Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Number: 747-53-2460

Original Issue: June 27, 2002

Revision 2: December 22, 2010

ATA System: 5312

SUBJECT: FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection

and Replacement

Export of this technology is controlled under the United States Export Administration Regulations (EAR) (15

CFR 730-774). An export license may be required before it is used for development, production or use by foreign

persons from specific countries. The controller of this data has the individual responsibility to abide by all export

laws.

ECCN: 9E991

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Copyright © 2002 The Boeing Company

Unpublished Work - All Rights Reserved

Boeing claims copyright in each page of this document only to the extent that the page contains copyrightable

subject matter. Boeing also claims copyright in this document as a compilation and/or collective work.

This document includes proprietary information owned by The Boeing Company and/or one or more third parties.

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3.0
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BLANK PAGE
Table of Contents

Revision Transmittal Sheet ............................................ 5

Summary ...................................................... 7

1. PLANNING INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

A. Effectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1. Airplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2. Spares Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

B. Concurrent Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

C. Reason . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

D. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

E. Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

F. Approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

G. Manpower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

H. Weight and Balance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

I. Electrical Load Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

J. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1. Existing Data: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2. Data supplied with this Service Bulletin: . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3. Installation Drawings Used in the Preparation of this Service Bulletin: . . . . . . . . . . . 35

K. Publications Affected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

L. Interchangeability and Intermixability of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

2. MATERIAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

A. Material - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

B. Industry Support Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

C. Parts Necessary For Each Airplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

1. Kits/Parts: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2. Parts and Materials Supplied by the Operator: . . . . . . . . . . . . . . . . . . . . . . . . 41

3. Parts Modified and Reidentified: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4. Parts Removed and Not Replaced: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

D. Parts Necessary to Change Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

E. Special Tooling - Price and Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

F. Special Tooling Necessary to do this Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . 42

3. ACCOMPLISHMENT INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

A. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

B. WORK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

FIGURE 1: LOGIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION . . . . . . 48

FIGURE 3: DOOR CORNER REVEAL - INSPECTION FOR CRACKS . . . . . . . . . . . . . . . . . 55

FIGURE 4: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION . . . . . . . . . . . . . . . . 57

FIGURE 5: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL REMOVAL AND INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT . . . . . . . . . . . . . . . . . 61

FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR . . . 70

FIGURE 8: DOOR CORNER REVEAL - WELD REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . 78

FIGURE 9: DOOR CORNER REVEAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION . . . . . . . . . . . . . . . . . . . . 83

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BOEING SERVICE BULLETIN 747-53-2460
FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL . 92

FIGURE 12: REMOVAL OF THE SHARP EDGE DETAIL FROM THE DOOR CORNER REVEAL . . . 95

FIGURE 13: REWORK OF A 1-PIECE LEFT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR

CORNER REVEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

FIGURE 14: REWORK OF A 1-PIECE RIGHT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR

CORNER REVEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

FIGURE 15: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS FOR CRACKS AND A

SHARP EDGE DETAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

FIGURE 16: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS WITH SHARP EDGE

DETAIL REMOVED FOR CRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

FIGURE 17: INSPECTION FOR ONE OR TWO-PIECE CORNER REVEALS . . . . . . . . . . . . . 103

Appendix A: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION PROCEDURE . . . . . . . 105

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BOEING SERVICE BULLETIN 747-53-2460
Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Revision Transmittal Sheet Number: 747-53-2460

Original Issue: June 27, 2002

Revision 2: December 22, 2010

ATA System: 5312

SUBJECT: FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection

and Replacement

This revision includes all pages of the service bulletin.

COMPLIANCE INFORMATION RELATED TO THIS REVISION

More work is necessary on airplanes line number 1038 - 1270 (new Group 4 airplanes) with corner reveals that

were:

1. Changed by rework of existing one-piece corner reveals into two-piece corner reveals in accordance with

Revision 1 of this service bulletin. On these airplanes, it is necessary to do a material type inspection to

determine if any reworked corner reveals are made from cast aluminum. Any reworked cast aluminum

corner reveals must be replaced with machined aluminum two-piece corner reveals or inspected periodically.

2. Inspected in accordance with Revision 1 of this service bulletin, but not replaced. On these airplanes, the

repeat inspection interval has been reduced, and at the next inspection for cracks also do a material type

inspection to determine if the reveals are made from cast aluminum. Cast aluminum corner reveals have

a shorter repeat inspection interval than machined aluminum corner reveals.

Continue to do repeat inspections in accordance with Revision 2 of this service bulletin on any airplane with

door 3 lower forward corner reveals that were previously inspected in accordance with Revision 1 of this service

bulletin, but not replaced, or that were replaced with new or repaired one-piece corner reveals.

No more work is necessary on any affected airplane on which one-piece corner reveals were replaced with new

machined aluminum two-piece corner reveals in accordance with Revision 1 of this service bulletin.

No airplanes were added to this service bulletin effectivity. However, based on an in-service report, airplanes

line number 1038 - 1270 were moved from Group 2 to new Group 4. Group 4 airplanes may have been delivered

with either cast aluminum or machined aluminum one-piece door 3 lower forward corner reveals. In addition,

airplanes that have been modified to the Boeing Converted Freighter (BCF) or the Large Cargo Freighter (LCF)

configuration have been removed from the service bulletin effectivity.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2008-18-07, is related to this service bulletin.

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REASON FOR REVISION

This revision is sent to include the changes that follow:

1. The Work Instructions in Paragraph 3.B. have been rewritten to make it more clear that the material type

inspection is only applicable to Group 1 and 4 airplanes, under certain conditions. The material type inspection

is necessary to identify castings if the operator wants to attempt to repair cracked one-piece lower forward

corner reveals by welding. The material type inspection is also necessary to identify castings if the operator

wants to rework uncracked one-piece reveals into two-piece reveals. Only machined aluminum reveals can

be reworked, cast aluminum reveals cannot be reworked.

2. New Part 6 has been added to Paragraph 3.B to show the additional work that is necessary on Group 4

airplanes on which uncracked one-piece corner reveals were reworked into two-piece corner reveals and

installed in accordance with Revision 1 of this service bulletin. As a result of the new in-service report noted

earlier, it is possible that Group 4 airplanes were delivered with cast aluminum corner reveals. Revision 1

of this service bulletin did not require a material type inspection on Group 4 airplanes to verify that any

one-piece corner reveal was not an aluminum casting prior to rework into a two-piece corner reveal.

3. The logic diagrams in FIGURE 1, FIGURE 15, and FIGURE 16 have been removed. The data previously

in those logic diagrams is included in the tables in Paragraph 1.E., Compliance.

4. Paragraph 1.E., Compliance and Paragraph 3.B., Work Instructions have been changed to allow operators

the option to replace a corner reveal prior to accomplishing any inspections of that reveal.

5. The Background and Action sections on the Summary page, Paragraph 1.C., Reason, and Paragraph 1.D.,

Description have been updated to agree with the new Work Instructions in Paragraph 3.B., and the service

history has been updated.

6. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, and in Figure 2, references to Parting

Agent G00771 have been replaced with Parting Agent AC962-73C. Parting agent G00771 is no longer

available. In Figure 10, an optional nut part number has been identified.

7. References to FAA Airworthiness Directive AD 2008-18-07 have been added. References to AD 96-23-05

were changed to AD 2007-12-11, which has superseded AD 96-23-05.

8. The data given in Information Notice 747-53-2460 IN 01 is included in this revision. IN 01 made general

clarifications to the instructions in Paragraph 3.B., Work Instructions.

Paragraph 1.A., Effectivity, shows changes of airplane operators. Each operator should examine the Effectivity

paragraph for changes.

Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity, to show the location

of important changes.

Pages with no vertical lines have no important changes.

REVISION HISTORY

Original Issue: June 27, 2002

Revision 1: February 13, 2007

Revision 2: December 22, 2010

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BOEING SERVICE BULLETIN 747-53-2460
Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Summary Number: 747-53-2460

Original Issue: June 27, 2002

Revision 2: December 22, 2010

ATA System: 5312

SUBJECT: FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection

and Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

CONCURRENT REQUIREMENTS

Refer to Paragraph 1.B., Concurrent Requirements.

BACKGROUND

Accomplishment of the inspection, repair, rework, or replacement of the Door 3 Lower Forward Corner Reveals

shown in this service bulletin will ensure the structural integrity of the attachment of the forward girt bar fitting

for the Door 3 escape slide. Failure of the Corner Reveal could cause the girt bar fitting to have misalignment

from the airplane structure. Girt bar misalignment from airplane structure would allow the door escape slide to

depart from the airplane if the slide was deployed for an evacuation resulting in injury to passengers and crew

using the escape slide.

The Door 3 Lower Forward Corner Reveals are either a casting that is made from 356 aluminum or a machined

part that is made from 6061 aluminum. The cast Corner Reveals have been found to crack while, prior to the

initial release of this service bulletin, there have been no reports of the machined Corner Reveals cracking. Most

of the airplanes in Group 1 of this service bulletin were delivered with the cast Corner Reveal, however, some

Group 1 airplanes had an option for the corner reveal to be machined from 6061 aluminum plate.

Deflection of the airplane structure at the door 3 frame causes the door corner reveal to crack.

Prior to the initial release of this service bulletin, seven operators have made a report of eleven cracked Door

3 Forward Corner Reveals. All eleven Corner Reveals were castings that were made from the 356 aluminum.

Since the initial release of this service bulletin, an operator has reported a cracked, machined 6061 aluminum

corner reveal. As a result of this report, airplanes line number 1038 through 1381, which were delivered with

machined 6061 aluminum corner reveals, were added to this service bulletin as Groups 2 and 3. In addition, it

has been found that airplanes line number 1038 through 1342 (Group 2 airplanes) may have been delivered

with a "sharp edge" detail on the outboard side of the reveal. This sharp edge detail can lead to reveal cracks.

Airplanes line number 1343 through 1381 (Group 3 airplanes) were reworked during production to remove the

sharp edge detail.

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Since the release of Revision 1 of this service bulletin, an operator has reported that a cracked cast aluminum

corner reveal was found on a Group 2 airplane, as defined in Revision 1 of this service bulletin. Boeing data

had indicated that those airplanes had all been delivered with machined aluminum corner reveals. Based on

that report, airplanes line number 1038 through 1270 were moved from Group 2 to Group 4.

The escape slide at Door 3 provides for a means of rapid egress from the airplane during an emergency

evacuation. In the automatic mode, girt bar locks at Door 3 are secured to the doorway sill by girt bar floor fittings.

When the Door 3 is opened, the escape slide is automatically deployed while secured to floor fittings. If a floor

fitting becomes misaligned due to a cracked Corner Reveal, the escape slide can become detached from the

airplane.

This service bulletin addresses cracking of the Corner Reveal located in the lower forward corner of the Main

Entry Door Number 3. Airplanes in Group 1 of this service bulletin were delivered with the Corner Reveal made

from a casting. After line number 1270, The subject part has been made from 6061aluminum plate.

The subject part is shown in Figure 3 identified as a Corner Reveal. In Service Bulletin 747-53A2378 the same

part has been identified as a Corner Casting or Support Fitting. AD 2007-12-11 identifies this part as a Corner

Casting.

This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original release and

Revision 1 of service bulletin 747-53A2378 for airplanes line number 1 through 868.

Boeing Service Related Problem (SRP)s 747-SRP-53-0129 and 747-SRP-53-0232 are related to this service

bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin

747-53A2378.

ACTION (PRR 85901-60RS)

Get access to the Door 3 lower forward corner reveal as shown in this service bulletin. Do a general visual

inspection of the installed lower forward corner reveals for one-piece or two-piece reveals. Also do an inspection

to determine the material type. No more work is necessary at any two-piece corner reveals that are found that

are not castings.

On Group 1, Configuration 1, Group 2 and Group 4 airplanes with affected corner reveals that are not castings,

do a detailed inspection of any installed one-piece corner reveal for a sharp edge detail. If a sharp edge detail

is found, rework the reveal to remove the sharp edge in accordance with this service bulletin. After rework, or

if no sharp edge detail is found, do a detailed inspection of the reveal for cracks.

On Group 1, Configuration 1 and Group 3 airplanes, do a detailed inspection of any installed one-piece reveal

for cracks.

If any crack is found, replace the reveal with a two-piece reveal. No more work is necessary after installation of

the two-piece reveal. As an alternative to replacement, cracked cast aluminum reveals (installed as an option

on Group 1 and 4 airplanes only) can be repaired by welding in accordance with this service bulletin. Continue

to do inspections of reveals that have been repaired until replaced with two-piece reveals.

If no cracks are found, continue to do inspections in accordance with this service bulletin until replaced with a

two-piece reveal. As an alternative to repeated inspections, one-piece reveals can be replaced with two-piece

reveals. No more work is required after installation of two-piece reveals.

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BOEING SERVICE BULLETIN 747-53-2460
EFFECTIVITY

747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D and 747SR airplanes.

Refer to Paragraph 1.A.1., Airplanes for the list of affected airplanes.

COMPLIANCE

Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-18-07 and AD 2007-12-11 are related

to this service bulletin.

Boeing recommends that inspections, repair, rework, or replacement of the Door 3 Forward Corner Reveal be

accomplished in accordance with the tables in Paragraph 1.E., Compliance .

This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original release and

Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868. Federal Aviation

Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin 747-53A2378.

INDUSTRY SUPPORT INFORMATION

Boeing warranty remedies are not available for the inspections and repair procedures given in this service

bulletin.

MANPOWER

Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION

Boeing Supplied Kits/Parts.

Refer to Paragraph 2.A., Material - Price and Availability.

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BOEING SERVICE BULLETIN 747-53-2460
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BOEING SERVICE BULLETIN 747-53-2460
Commercial 

Airplanes 747

Service Bulletin

SPECIAL ATTENTION

Number: 747-53-2460

Original Issue: June 27, 2002

Revision 2: December 22, 2010

ATA System: 5312

SUBJECT: FUSELAGE - Number 3 Main Entry Door - Lower Forward Corner Reveal - Inspection

and Replacement

BOEING RECOMMENDS THAT EACH OPERATOR EXAMINE THIS SERVICE BULLETIN IMMEDIATELY.

1. PLANNING INFORMATION

A. Effectivity

1. Airplanes

Refer to Service Bulletin Index Document D6-30300 Part 3 for Airplane Variable Number, Line

Number, and Serial Number data.

This service bulletin is for the airplanes shown below. An equivalent change is on subsequent

production airplanes. Refer to PRR 85901-009SK and PRR 85901-60RS for data about this change.

NOTE: This service bulletin is not applicable if Door 3 has been deactivated. However, if Door

3 has been deactivated and then reactivated, this service bulletin is applicable.

GROUP CONFIGURATION DESCRIPTION

747 airplanes line number 1 through 1037, except 747SP, 747-200F,

and 747-400F airplanes, and airplanes modified by Boeing to the

Special Freighter, Boeing Converted Freighter, or Large Cargo

Freighter configuration.

1 -

With the Door 3 lower corner reveal not previously replaced in

accordance with the original issue of this service bulletin.

1

With the Door 3 lower corner reveal previously replaced in accordance

with the original issue of this service bulletin.

2

747 airplanes line number 1272 - 1342, except 747-400F airplanes

and airplanes modified by Boeing to the Boeing Converted Freighter

or Large Cargo Freighter configuration.

2 -

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GROUP CONFIGURATION DESCRIPTION

747 airplanes line number 1343 - 1381, except 747-400F airplanes

and airplanes modified by Boeing to the Boeing Converted Freighter

or Large Cargo Freighter configuration.

3 -

747 airplanes line number 1038 -1270, except 747SP, 747-200F,

and 747-400F airplanes and airplanes modified by Boeing to the

Boeing Converted Freighter or Large Cargo Freighter configuration.

4 -

Airplane Models:

747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-300, 747-400, 747-400D,

747SR

Variable Number Group

RA001 - RA025 1

RA027 - RA028 1

RA030 - RA032 1

RA034 1

RA104 - RA110 1

RA113 - RA115 1

RA164 1

RA201 - RA203 1

RA216 - RA217 1

RA245 - RA246 1

RA251 - RA266 1

RA301 - RA318 1

RA351 - RA360 1

RA369 - RA373 1

RA401 - RA418 1

RA501 - RA502 1

RA521 - RA523 1

RA525 - RA528 1

RA532 - RA548 1

RA551 - RA552 1

RA559 - RA561 1

RA581 - RA582 1

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RA585 1

RA601 - RA602 1

RA631 1

RA633 1

RA651 - RA652 1

RA671 - RA677 1

RA701 - RA702 1

RA721 - RA731 1

RA741 - RA745 1

RA749 - RA750 1

RA761 - RA762 1

RA781 - RA784 1

RA903 - RA909 1

RB001 - RB016 1

RB042 1

RB044 1

RB071 - RB075 1

RB101 - RB102 1

RB411 - RB413 1

RB421 1

RB601 - RB603 1

RB681 - RB695 1

RB697 1

RB711 1

RB721 - RB723 1

RB741 - RB748 1

RD001 - RD004 1

RD021 - RD022 1

RD042 1

RD045 - RD054 1

RD056 - RD059 1

RD071 - RD072 1

RD081 1

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RD091 - RD092 1

RD101 - RD104 1

RD121 - RD127 1

RD131 - RD141 1

RD143 1

RD166 - RD167 1

RD171 - RD172 1

RD181 - RD183 1

RD201 - RD204 1

RD221 - RD224 1

RD226 1

RD231 - RD232 1

RD241 - RD243 1

RD251 - RD262 1

RD271 - RD272 1

RD291 - RD292 1

RD311 1

RD351 - RD357 1

RD381 - RD383 1

RD413 - RD414 1

RD421 - RD426 1

RD431 - RD435 1

RD451 - RD456 1

RD471 - RD475 1

RD513 - RD519 1

RD531 - RD533 1

RD561 1

RD571 1

RD591 - RD593 1

RD603 - RD607 1

RD621 1

RD644 - RD645 1

RD647 - RD649 1

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RD651 - RD659 1

RD661 1

RD671 1

RD681 - RD682 1

RD692 1

RD701 - RD702 1

RD721 - RD722 1

RD741 - RD742 1

RD751 1

RD753 - RD755 1

RD761 1

RD771 - RD775 1

RD781 - RD783 1

RD791 - RD792 1

RE001 1

RF001 - RF006 2

RJ131 - RJ133 1

RJ151 - RJ152 1

RJ301 - RJ303 1

RJ321 - RJ322 1

RJ331 - RJ333 1

RM001 - RM005 4

RM006 - RM007 2

RM010 2

RM011 - RM012 4

RM013 2

RM021 - RM024 4

RM026 - RM027 4

RM028 - RM030 2

RM036 - RM039 4

RM040 2

RM041 - RM043 4

RM044 - RM045 2

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RM051 4

RM052 - RM053 2

RM071 4

RM081 - RM084 4

RM091 4

RM096 - RM097 4

RM116 - RM117 4

RM126 - RM127 4

RM129 - RM131 4

RM132 2

RM136 - RM147 4

RM156 - RM158 4

RM166 - RM177 4

RM191 - RM192 4

RM231 - RM233 4

RM241 - RM244 4

RM245 - RM246 2

RM261 - RM264 4

RM316 - RM318 4

RM331 - RM333 4

RM341 4

RM351 4

RM352 - RM355 2

RM366 - RM367 2

RM401 - RM402 2

RM403 3

RM426 2

RM431 2

RM441 - RM443 3

RM445 3

RM801 - RM802 4

RM803 2

RM811 - RM813 4

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RS001 - RS002 1

RS201 1

RS211 - RS212 1

RS221 - RS222 1

RS231 - RS241 1

RS251 - RS259 1

RS263 1

RS265 - RS268 1

RS271 - RS276 1

RS291 - RS292 1

RS301 - RS306 1

RS311 - RS320 1

RS331 - RS333 1

RS341 - RS342 1

RS699 1

RS701 - RS703 1

RS711 - RS713 1

RS731 - RS732 1

RS742 1

RS751 - RS752 1

RS761 1

RS781 - RS782 1

RT001 - RT011 1

RT012 - RT014 4

RT034 - RT035 4

RT041 - RT047 1

RT061 1

RT073 - RT074 1

RT101 - RT103 1

RT121 1

RT131 - RT134 1

RT135 - RT137 4

RT151 - RT152 4

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RT162 - RT163 1

RT165 - RT168 4

RT401 - RT412 1

RT431 - RT441 1

RT442 - RT447 4

RT451 - RT455 1

RT457 - RT460 1

RT462 - RT468 1

RT469 4

RT471 - RT498 1

RT499 4

RT502 - RT505 1

RT511 - RT512 1

RT514 - RT515 1

RT517 1

RT521 - RT523 1

RT525 1

RT526 - RT527 4

RT529 - RT530 4

RT531 - RT535 1

RT551 - RT568 1

RT571 1

RT580 - RT584 1

RT585 - RT590 4

RT591 1

RT601 - RT622 1

RT623 - RT630 4

RT633 - RT635 1

RT636 - RT640 4

RT641 1

RT643 - RT654 1

RT671 - RT673 1

RT681 - RT682 1

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RT691 - RT697 1

RT698 - RT699 4

RT701 - RT704 1

RT711 - RT717 1

RT741 - RT742 1

RT744 - RT749 1

RT750 4

RT753 - RT755 1

RT756 - RT757 4

RT776 - RT777 1

RT783 - RT784 1

RT801 - RT803 4

RT811 - RT814 4

RT831 - RT836 4

RT861 - RT864 1

RT877 - RT879 1

RT880 4

RT931 - RT932 1

RT945 1

RT946 - RT949 4

RT951 - RT954 1

RT955 4

RT966 1

RU001 - RU004 1

RU005 - RU006 4

RU016 - RU017 4

RU031 - RU032 1

RU051 - RU052 1

RU059 - RU060 4

RU061 - RU062 1

RU081 - RU082 1

RU083 4

RU101 - RU102 4

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BOEING SERVICE BULLETIN 747-53-2460
Variable Number Group

RU121 - RU132 4

RU801 - RU809 1

RU831 - RU839 1

RU840 - RU841 4

2. Spares Affected

None.

B. Concurrent Requirements

The service bulletin listed below can be done before or at the same time as this service bulletin:

Company Service Bulletin Description

Service Bulletin 747-53A2378 accomplishes

an inspection of the support structure under

the Corner Reveal for corrosion. (a) (b)

747-53A2378 Revision 2, Revision 3, or

Revision 4

Boeing

(a) At Door 3 only, for airplanes with common effectivity.

(b) Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service Bulletin

747-53A2378.

C. Reason

Accomplishment of the inspection, repair, rework, or replacement of the Door 3 Lower Forward Corner

Reveals shown in this service bulletin will ensure the structural integrity of the attachment of the forward

girt bar fitting for the Door 3 escape slide. Failure of the Corner Reveal could cause the girt bar fitting

to have misalignment from the airplane structure. Girt bar misalignment from airplane structure would

allow the door escape slide to depart from the airplane if the slide was deployed for an evacuation

resulting in injury to passengers and crew using the escape slide.

The Door 3 Lower Forward Corner Reveals are either a casting that is made from 356 aluminum or a

machined part that is made from 6061 aluminum. The cast Corner Reveals have been found to crack

while, prior to the initial release of this service bulletin, there have been no reports of the machined

Corner Reveals cracking. Most of the airplanes in Group 1 of this service bulletin were delivered with

the cast Corner Reveal, however, some Group 1 airplanes had an option for the corner reveal to be

machined from 6061 aluminum plate.

Deflection of the airplane structure at the door 3 frame causes the door corner reveal to crack.

Prior to the initial release of this service bulletin, seven operators have made a report of eleven cracked

Door 3 Forward Corner Reveals. All eleven Corner Reveals were castings that were made from the

356 aluminum.

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BOEING SERVICE BULLETIN 747-53-2460
Since the initial release of this service bulletin, an operator has reported a cracked, machined 6061

aluminum corner reveal. As a result of this report, airplanes line number 1038 through 1381, which

were delivered with machined 6061 aluminum corner reveals, were added to this service bulletin as

Groups 2 and 3. In addition, it has been found that airplanes line number 1038 through 1342 (Group

2 airplanes) may have been delivered with a "sharp edge" detail on the outboard side of the reveal.

This sharp edge detail can lead to reveal cracks. Airplanes line number 1343 through 1381 (Group 3

airplanes) were reworked during production to remove the sharp edge detail.

Since the release of Revision 1 of this service bulletin, an operator has reported that a cracked cast

aluminum corner reveal was found on a Group 2 airplane, as defined in Revision 1 of this service

bulletin. Boeing data had indicated that those airplanes had all been delivered with machined aluminum

corner reveals. Based on that report, airplanes line number 1038 through 1270 were moved from Group

2 to Group 4.

The escape slide at Door 3 provides for a means of rapid egress from the airplane during an emergency

evacuation. In the automatic mode, girt bar locks at Door 3 are secured to the doorway sill by girt bar

floor fittings. When the Door 3 is opened, the escape slide is automatically deployed while secured to

floor fittings. If a floor fitting becomes misaligned due to a cracked Corner Reveal, the escape slide

can become detached from the airplane.

This service bulletin address cracking of the Corner Reveal located in the lower forward corner of the

Main Entry Door Number 3. The airplanes in Group 1 of this service bulletin were delivered with the

cast Corner Reveal. After line number 1270, the subject part has been made from 6061 aluminum

plate.

The subject part is shown in Figure 3 identified as a Corner Reveal. In Service Bulletin 747-53A2378

the same part has been identified as a Corner Casting or Support Fitting. AD 2007-12-11 identifies

this part as a Corner Casting.

This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original

release and Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868.

Boeing Service Related Problem (SRP)s 747-SRP-53-0129 and 747-SRP-53-0232 are related to this

service bulletin.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service

Bulletin 747-53A2378.

Revision 1 is sent to add inspection and modification of one-piece Door 3 lower forward corner reveals

that are machined from 6061 aluminum. Installation of machined aluminum corner reveals had been

considered terminating action for the inspections in this service bulletin, but since the initial release of

this service bulletin, Boeing has received a report of a cracked machined aluminum corner reveal.

Replacement of the one-piece machined aluminum corner reveals with two-piece machined aluminum

corner reveals is now considered terminating action. The machined 6061 aluminum one-piece corner

reveals were delivered on airplanes line number 1038 through 1381. In addition, airplanes line number

1038 - 1342 and those airplanes previously modified as shown in this service bulletin may have corner

reveals installed that have a "sharp edge" detail at the forward edge. This sharp edge can lead to

cracks. On these airplanes, an inspection is included to find and remove the sharp edge. The

Accomplishment Instructions have been rewritten, and Figures 9 through 16 have been added to show

the new inspections, modifications, and corner reveal replacement instructions. Revision 1 also clarifies

Views A and View B in Figures 6 and 7. The change to Views A and B show that the two fasteners,

identified by fastener code "B," are installed under the serrated plate and not through the serrated plate.

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BOEING SERVICE BULLETIN 747-53-2460
Part quantities are clarified in Figure 6, Circle Notes 28 and 29, and in Figure 7, Circle Notes 16 and

17. Clarified the nutplate locations in Figure 7, View C illustration. Revision 1 also adds the G00771

bulk consumable material to the Paragraph 2.C.2. "Parts and Materials Supplied by the Operator."

References to FAA Notice of Proposed Rulemaking (NPRM), FAA Docket Number 2002-NM-285-AD,

have been added.

Revision 2 includes these changes:

1. The Work Instructions in Paragraph 3.B. have been rewritten to make it more clear that the material

type inspection is only applicable to Group 1 and 4 airplanes, under certain conditions. The material

type inspection is necessary to identify castings if the operator wants to attempt to repair cracked

one-piece lower forward corner reveals by welding. The material type inspection is also necessary

to identify castings if the operator wants to rework uncracked one-piece reveals into two-piece

reveals. Only machined aluminum reveals can be reworked, cast aluminum reveals cannot be

reworked.

2. New Part 6 has been added to Paragraph 3.B to show the additional work that is necessary on

Group 4 airplanes on which uncracked one-piece corner reveals were reworked into two-piece

corner reveals and installed in accordance with Revision 1 of this service bulletin. As a result of

the new in-service report noted earlier, it is possible that Group 4 airplanes were delivered with

cast aluminum corner reveals. Revision 1 of this service bulletin did not require a material type

inspection on Group 4 airplanes to verify that any one-piece corner reveal was not an aluminum

casting prior to rework into a two-piece corner reveal.

3. The logic diagrams in FIGURE 1, FIGURE 15, and FIGURE 16 have been removed. The data

previously in those logic diagrams is included in the tables in Paragraph 1.E., Compliance.

4. Paragraph 1.E., Compliance and Paragraph 3.B., Work Instructions have been changed to allow

operators the option to replace a corner reveal prior to accomplishing any inspections of that reveal.

5. The Background and Action sections on the Summary page, Paragraph 1.C., Reason, and

Paragraph 1.D., Description have been updated to agree with the new Work Instructions in

Paragraph 3.B., and the service history has been updated.

6. In Paragraph 2.C.2., Parts and Materials Supplied by the Operator, and in Figure 2, references to

Parting Agent G00771 have been replaced with Parting Agent AC962-73C. Parting agent G00771

is no longer available. In Figure 10, an optional nut part number has been identified.

7. References to FAA Airworthiness Directive AD 2008-18-07 have been added. References to AD

96-23-05 were changed to AD 2007-12-11, which has superseded AD 96-23-05.

8. The data given in Information Notice 747-53-2460 IN 01 is included in this revision. IN 01 made

general clarifications to the instructions in Paragraph 3.B., Work Instructions.

D. Description

Get access to the Door 3 lower forward corner reveal as shown in this service bulletin. Do a general

visual inspection of the installed lower forward corner reveals for one-piece or two-piece reveals. Also

do an inspection to determine the material type. No more work is necessary at any two-piece corner

reveals that are found that are not castings.

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BOEING SERVICE BULLETIN 747-53-2460
On Group 1, Configuration 1, Group 2 and Group 4 airplanes with affected corner reveals that are not

castings, do a detailed inspection of any installed one-piece corner reveal for a sharp edge detail. If a

sharp edge detail is found, rework the reveal to remove the sharp edge in accordance with this service

bulletin. After rework, or if no sharp edge detail is found, do a detailed inspection of the reveal for

cracks.

On Group 1, Configuration 1 and Group 3 airplanes, do a detailed inspection of any installed one-piece

reveal for cracks.

If any crack is found, replace the reveal with a two-piece reveal. No more work is necessary after

installation of the two-piece reveal. As an alternative to replacement, cracked cast aluminum reveals

(installed as an option on Group 1 and 4 airplanes only) can be repaired by welding in accordance with

this service bulletin. Continue to do inspections of reveals that have been repaired until replaced with

two-piece reveals.

If no cracks are found, continue to do inspections in accordance with this service bulletin until replaced

with a two-piece reveal. As an alternative to repeated inspections, one-piece reveals can be replaced

with two-piece reveals. No more work is required after installation of two-piece reveals.

This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original

release and Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service

Bulletin 747-53A2378.

Revision 1 - More work is necessary on airplanes changed as shown in the initial release of this service

bulletin. If the corner reveal was replaced as shown in the initial release of this service bulletin, do more

inspections for cracks or a sharp edge detail as shown in this revision. If no cracks are found, continue

to do inspections, rework or replace the corner reveal as shown in this revision. If a sharp edge detail

is found, rework or replace the corner reveal as shown in this revision. Continue to do inspections as

shown in this revision until the one-piece corner reveal is replaced with a two-piece corner reveal.

Revision 2 - More work is necessary on airplanes line number 1038 - 1270 (new Group 4 airplanes)

with corner reveals that were:

1. Changed by rework of existing one-piece corner reveals into two-piece corner reveals in accordance

with Revision 1 of this service bulletin. On these airplanes, it is necessary to do a material type

inspection to determine if any reworked corner reveals are made from cast aluminum. Any reworked

cast aluminum corner reveals must be replaced with machined aluminum two-piece corner reveals

or inspected periodically.

2. Inspected in accordance with Revision 1 of this service bulletin, but not replaced. On these airplanes,

the repeat inspection interval has been reduced, and at the next inspection for cracks also do a

material type inspection to determine if the reveals are made from cast aluminum. Cast aluminum

corner reveals have a shorter repeat inspection interval than machined aluminum corner reveals.

Continue to do repeat inspections in accordance with Revision 2 of this service bulletin on any airplane

with door 3 lower forward corner reveals that were previously inspected in accordance with Revision

1 of this service bulletin, but not replaced, or that were replaced with new or repaired one-piece corner

reveals.

No more work is necessary on any affected airplane on which one-piece corner reveals were replaced

with new machined aluminum two-piece corner reveals in accordance with Revision 1 of this service

bulletin.

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BOEING SERVICE BULLETIN 747-53-2460
The work in this service bulletin is done in the maintenance zone(s) given below.

Group 1:

Affected Maintenance Zones

Model Zone

747-100, 747-100B, 747-100B 241, 242

SUD, 747-200B, 747-200C,

747-300, 747-400, 747-400D,

747SR

Group 2-3:

Affected Maintenance Zones

Model Zone

747-400 241, 242

Group 4:

Affected Maintenance Zones

Model Zone

747-400, 747-400D 241, 242

E. Compliance

Federal Aviation Administration (FAA) Airworthiness Directives AD 2008-18-07 and AD 2007-12-11

are related to this service bulletin.

This service bulletin replaces the inspection of Door 3 Lower Forward Corner Reveal in the original

release and Revision 1 of Service Bulletin 747-53A2378 for airplanes line number 1 through 868.

Federal Aviation Administration (FAA) Airworthiness Directive AD 2007-12-11 is related to Service

Bulletin 747-53A2378 .

Previously Inspected or Changed in

Accordance With Revision 1 of this

Service Bulletin

Not Previously Inspected or Changed

in Accordance With Revision 1 of this

Service Bulletin

Airplane Group

Group 1, Configuration 1 Use Table 2 Use Table 5

Group 1, Configuration 2 Use Table 3 Use Table 6

Group 2 Use Table 3 Use Table 6

Group 3 Use Table 4 Use Table 4

Group 4 Use Table 2 Use Table 1

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BOEING SERVICE BULLETIN 747-53-2460
Group 4:

Table 1: More Work Required on Group 4 Airplanes Previously Inspected or Changed in Accordance

With Revision 1 of This Service Bulletin

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs Later)Condition Action

Within 1,000 -

flight-cycles

after the Revision 2 date of

this service

bulletin.

Within 3,000

flight-cycles

after the previous inspection or rework

done in accordance with

Revision 1 of

this service

bulletin.

7,000 total

flight-cycles

Get access to the corner reveals and do a

material type inspection to determine if the

corner reveals are

castings in accordance with Paragraph

3.B., PART 6, or

Any affected Group 4

airplanes previously

inspected in accordance with Revision 1

of this service bulletin:

1. But the corner reveals were not replaced. or

2. The corner reveals

were replaced with

two-piece reveals that

were made by rework

of existing one-piece

reveals in accordance

with Revision 1 of this

service bulletin.

Replace the corner

reveal with a new twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

No more work is nec- - -

essary.

Any affected Group 4

airplanes previously

inspected in accordance with Revision 1

of this service bulletin,

with new two-piece

corner reveals installed.

Within 10,000 - - See Table 8

flight-cycles

after the reveal was replaced.

Inspect the corner reveal for cracks in accordance with Table

8, or

Any affected Group 4

airplanes previously

inspected in accordance with Revision 1

of this service bulletin,

with new one-piece

corner reveals installed.

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

No more work is nec- - -

essary.

Any two-piece corner

reveal that is found to

not be a casting.

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BOEING SERVICE BULLETIN 747-53-2460
Group 4:

Table 1: More Work Required on Group 4 Airplanes Previously Inspected or Changed in Accordance

With Revision 1 of This Service Bulletin

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs Later)Condition Action

Before further See Table 8

flight.

Inspect the corner reveal for cracks in accordance with Table

8, or

Any one or two-piece

corner reveal that is

found to be a casting.

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

Within 6,000 - See Table 8

flight-cycles

after the previous inspection done in

accordance

with Revision

1 of this service bulletin.

10,000 total

flight-cycles

Inspect the corner reveal for cracks in accordance with Table

8, or

Any one-piece corner

reveal that is found to

not be a casting.

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

Group 1, Configuration 1; Group 4:

Table 2: Door 3 Lower Forward Corner Reveal Inspection on Group 1, Configuration 1 and Group 4 Airplanes Not Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs Later)Condition Action

Within 1,000 - -

flight-cycles

after the effective date of

AD 2008-18-

07.

1,500 total

flight-cycles

Do a material type inspection to determine

if the corner reveals

are casting in accordance with Paragraph

3.B., PART 6, or

All affected airplanes

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

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BOEING SERVICE BULLETIN 747-53-2460
Group 1, Configuration 1; Group 4:

Table 2: Door 3 Lower Forward Corner Reveal Inspection on Group 1, Configuration 1 and Group 4 Airplanes Not Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs Later)Condition Action

Cast corner reveal

found

Within 3,000 See Table 8

flight-cycles

after the previous inspection of the

door 3 corner

reveal in accordance with

SB 747-

53A2378.

Within 2,000

flight-cycles

after the effective date of

AD 2008-18-

07.

7,000 total

flight-cycles.

Inspect the corner reveal for cracks in accordance with Table

8, or

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

Before further - - See Table 8

flight.

Inspect the corner reveal for a sharp edge

detail in accordance

with Table 7 and

Group 4; Cast corner

reveal not found

Inspect the corner reveal for cracks in accordance with Table

8, or

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

Before further - - See Table 8

flight.

Inspect the corner reveal for cracks in accordance with Table

8, or

Group 1, Configuration 1; Cast corner reveal not found

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

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BOEING SERVICE BULLETIN 747-53-2460
Group 1, Configuration 2; Group 2:

Table 3: Door 3 Lower Forward Corner Reveal Inspection on Group 1, Configuration 2 and Group 2 Airplanes Not Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time (Whichever Occurs Later)

Within 1,000 flight- See Table 8

cycles after the effective date of AD

2008-18-07.

Within 1,500 flight-cycles

after the corner reveal was

replaced in accordance

with the original issue of

this service bulletin.

Inspect the corner reveal for a sharp edge

detail in accordance

with Table 7 and

Group 1, Configuration 2: All affected airplanes

Inspect the corner reveal for cracks in accordance with Table 8, or

Replace the corner reveal with a two-piece

corner reveal in accordance with Paragraph

3.B., PART 3.

Within 1,000 flight- See Table 8

cycles after the effective date of AD

2008-18-07.

Inspect the corner re- 1,500 total flight-cycles.

veal for a sharp edge

detail in accordance

with Table 7 and

Group 2: All affected airplanes

Inspect the corner reveal for cracks in accordance with Table 8, or

Replace the corner reveal with a two-piece

corner reveal in accordance with Paragraph

3.B., PART 3.

Within 6,000 flight- See Table 8

cycles.

Inspect the corner re- 10,000 total flight-cycles

veal for cracks in accordance with Table 8, or

No crack, and no

sharp edge found.

Replace the corner reveal with a two-piece

corner reveal in accordance with Paragraph

3.B., PART 3.

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BOEING SERVICE BULLETIN 747-53-2460
Group 3:

Table 4: Door 3 Lower Forward Corner Reveal Inspection

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 1,000 flight- See Table 8

cycles after the effective date of AD

2008-18-07.

10,000 total

flight-cycles

Inspect the corner reveal for

cracks in accordance with

Table 8, or

Airplanes not previously inspected in accordance with

Revision 1 of this service

bulletin. Replace the corner reveal

with a two-piece corner reveal in accordance with

Paragraph 3.B., PART 3.

Within 6,000 - See Table 8

flight-cycles

after the previous inspection.

Inspect the corner reveal for

cracks in accordance with

Table 8, or

Airplanes previously inspected in accordance with

Revision 1 of this service

bulletin, and the existing

corner reveal was not replaced with a new onepiece corner reveal.

Replace the corner reveal

with a two-piece corner reveal in accordance with

Paragraph 3.B., PART 3.

Within - See Table 8

10,000 flightcycles after

the reveal

was replaced.

Inspect the corner reveal for

cracks in accordance with

Table 8, or

Airplanes previously inspected in accordance with

Revision 1 of this service

bulletin, and the corner reveal was replaced with a

new one-piece corner reveal.

Replace the corner reveal

with a two-piece corner reveal in accordance with

Paragraph 3.B., PART 3.

Reveal was previously re- No more work is necessary. - -

placed with a two-piece reveal in accordance with

Revision 1 of this service

bulletin.

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BOEING SERVICE BULLETIN 747-53-2460
Group 1, Configuration 1:

Table 5: Inspection of Door 3 Lower Forward Corner Reveals on Group 1, Configuration 1 Airplanes

Previously Inspected or Changed in Accordance With Revision 1 of this Service Bulletin

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever Occurs Later)Condition Action

Within 10,000 - - See Table 8

flight-cycles

after the reveal was replaced.

Inspect the corner reveal for cracks in accordance with Table

8, or

Airplanes previously

inspected in accordance with Revision 1

of this service bulletin,

and the corner reveal

was replaced with a

new one-piece corner

reveal.

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

within 6,000 - See Table 8

flight-cycles

after the previous inspection.

10,000 total

flight-cycles

Inspect the corner reveal for cracks in accordance with Table

8, or

Airplanes previously

inspected in accordance with Revision 1

of this service bulletin,

and the corner reveal

is not a casting and

was not replaced.

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

Within 3,000 See Table 8

flight-cycles of

the previous

inspection of

the door 3

corner reveal

in accordance

with Service

Bulletin 747-

53A2378.

Within 2,000

flight-cycles

after the effective date of

AD 2008-18-

07.

7,000 total

flight-cycles

Inspect the corner reveal for cracks in accordance with Table

8, or

Airplanes previously

inspected in accordance with Revision 1

of this service bulletin,

and the corner reveal

is a casting and was

not replaced.

Replace the corner

reveal with a twopiece corner reveal in

accordance with

Paragraph 3.B., PART

3.

No more work is nec- - -

essary.

Reveal was previously

replaced with a twopiece reveal in accordance with Revision 1

of this service bulletin.

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BOEING SERVICE BULLETIN 747-53-2460
Group 1, Configuration 2; Group 2:

Table 6: Corner Reveal Inspection on Airplanes Previously Inspected or Changed in Accordance With

Revision 1 of this Service Bulletin

Repeat Interval

(Not to Exceed)

Compliance Time (Whichever

Occurs Later)

Condition Action

Within 6,000 flight- See Table 8

cycles of the previous inspection in

accordance with

Revision 1 of this

service bulletin.

10,000 total

flight-cycles

Inspect the corner reveal for

cracks in accordance with

Table 8, or

Airplanes previously inspected in accordance with

Revision 1 of this service

bulletin, but the corner reveal was not replaced. Replace the corner reveal

with a two-piece corner reveal in accordance with

Paragraph 3.B., PART 3.

Within - See Table 8

10,000 flightcycles after

the reveal

was replaced.

Inspect the corner reveal for

cracks in accordance with

Table 8, or

Airplanes previously inspected in accordance with

Revision 1 of this service

bulletin, and the corner reveal was replaced with a

new one-piece corner reveal.

Replace the corner reveal

with a two-piece corner reveal in accordance with

Paragraph 3.B., PART 3.

Reveal was previously re- No more work is necessary. - -

placed with a two-piece reveal in accordance with

Revision 1 of this service

bulletin.

Group 1, Configuration 2; Group 2, 4:

Table 7 - Inspection of One-Piece Corner Reveals For a Sharp Edge Detail

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do a detailed inspection of the installed

lower forward corner reveal for a sharp

edge detail, in accordance with Paragraph

3.B., PART 1.

Group 4 airplanes: At any

one-piece corner reveal

confirmed to not be a casting.

Before further -

flight.

Do a detailed inspection of the installed

lower forward corner reveal for a sharp

edge detail, in accordance with Paragraph

3.B., PART 1.

Group 1, Configuration 2 and

Group 2 airplanes: At any

one-piece corner reveal

found.

Before further -

flight.

Do a detailed inspection of the corner reveal for cracks, in accordance with Table

8.

No sharp edge detail found.

Before further -

flight.

Rework the corner reveal to remove the

sharp edge detail in accordance with

Paragraph 3.B., PART 1. After rework, do

a detailed inspection of the corner reveal

for cracks, in accordance with Table 8

Sharp edge detail found

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BOEING SERVICE BULLETIN 747-53-2460
Group 1, 2, 3, 4: Table 8 - Inspection of Corner Reveals for Cracks

Repeat Interval

(Not to Exceed)

Condition Action Compliance Time

Before further -

flight.

Do a detailed inspection of the corner reveal for cracks, in accordance with Paragraph 3.B., PART 2.At any corner reveal.

3,000 flight-cyclesRepeat the detailed inspection in accor- -

dance with Paragraph 3.B., PART 2.

Group 1, Configuration 1 and

Group 4 airplanes: No

cracks found, on a reveal

confirmed to be a casting.

6,000 flight-cycles.Repeat the detailed inspection in accor- -

dance with Paragraph 3.B., PART 2.

Group 1, Configuration 1 and

Group 4 airplanes: No

cracks found, on a reveal

confirmed to not be a casting.

Group 1, Configuration 2,

Group 2 and Group 3 airplanes: No cracks found.

Before further -

flight.

Install a two-piece corner reveal in accordance with Paragraph 3.B., PART 3.Group 1, Configuration 1 and

Group 4 airplanes: Any crack

found on a reveal confirmed

to not be a casting.

Group 1, Configuration 2,

Group 2 and Group 3 airplanes: Any crack found.

Before further -

flight.

Repair cracks in accordance with Paragraph 3.B., PART 4, andGroup 1, Configuration 1 and

Group 4 airplanes: Any crack

found on any reveal confirmed to be a casting. 3,000 flight-cycles

Within 3,000 flightcycles.Do a detailed inspection of the corner reveal for cracks, in accordance with Table

9. or

Before further -

flight.

Install a two-piece corner reveal in accordance with Paragraph 3.B., PART 3.

NOTE: After installation of two-piece door 3 lower forward corner reveals, continue inspections in

accordance with the operator's maintenance plan. There are no additional inspections required

by this service bulletin.

F. Approval

This service bulletin was examined by the Federal Aviation Administration (FAA). The changes specified

in this service bulletin comply with the applicable regulations and are FAA approved, as well as European

Aviation Safety Agency (EASA)/Joint Aviation Authorities (JAA) approved for all EASA/JAA approved

airplanes listed in the service bulletin effectivity. This service bulletin and its approval were based on

the airplane in its original Boeing delivery configuration or as modified by other approved Boeing

changes.

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BOEING SERVICE BULLETIN 747-53-2460
If an airplane has a non-Boeing modification or repair that affects a component or system also affected

by this service bulletin, the operator is responsible for obtaining appropriate regulatory agency approval

before incorporating this service bulletin.

The Manager of the FAA Seattle Aircraft Certification Office (ACO) approves the repair and replacement

actions with the corresponding compliance times specified in Tables 2, 3, 5, 6, 7 and 8, under paragraph

1.E., "Compliance," of Service Bulletin 747-53-2460, Revision 2 as an AMOC to the repair and

replacement actions with the corresponding compliance times required by paragraph paragraph (q) of

AD 2007-12-11. When this service bulletin specifies contacting Boeing for repair instructions, the repair

instructions must be approved by the FAA in accordance with paragraph (w) of the AD. These approvals

are applicable to the Main Entry Door (MED) 3 lower forward corner reveal only. All provisions of AD

2007-12-11 that are not specifically referenced in this paragraph, including but not limited to performing

repeat inspections in accordance with paragraph (o) until a two-piece reveal is installed in accordance

with Service Bulletin 747-53-2460 Revision 2, remain fully applicable and must be complied with.

The Manager of the FAA Seattle ACO also approves the inspection, rework, repair and replacement

actions with the corresponding compliance times specified in Tables 1 through 8, under paragraph

1.E., "Compliance," of Service Bulletin 747-53-2460, Revision 2 as an AMOC to the inspection, rework,

repair and replacement actions with the corresponding compliance times required by paragraphs (g),

(h), (i), (j) and (k) of AD 2008-18-07. When this service bulletin specifies contacting Boeing for repair

instructions, the repair instructions must be approved by the FAA in accordance with paragraph (p) of

the AD. All provisions of AD 2008-18-07 that are not specifically referenced in this paragraph, including

but not limited to performing repeat inspections until a two-piece reveal is installed in accordance with

Service Bulletin 747-53-2460 Revision 2, remain fully applicable and must be complied with.

G. Manpower

The table below shows an estimate of the task-hours necessary to do this inspection and repair or

replacement of the Door 3 Forward Corner Reveal for each airplane. This estimate is for direct labor

only, done by an experienced crew. Adjust the estimate with operator task-hour data if necessary. The

estimate does not include lost time. These are some examples of lost time:

— Time to adjust to the workplace

— Time to schedule the work

— Time to examine the work

— Time to cure the materials

— Time to make the parts

— Time to find the tools.

INSPECTION FOR CRACKS

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 5.0 2.5

Inspect 2 1.0 .5

Close Access 2 5.0 2.5

TOTAL FOR EACH AIRPLANE 11.0 5.5

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BOEING SERVICE BULLETIN 747-53-2460
MATERIAL TYPE INSPECTION

Number of Per- Task-Hours Elapsed Hours

sons

Task

Remove Finish 2 1.0 .5

Test 2 .5 .25

Restore Finish 2 1.0 .5

TOTAL FOR EACH AIRPLANE 2.5 1.25

Corner Reveal Removal and Installation

Number of Per- Task-Hours Elapsed Hours

sons

Task

Open Access 2 4.0 2.0

Removal / Install 2 8.0 4.0

Close Access 2 4.0 2.0

Test 2 1.0 .50

TOTAL FOR EACH AIRPLANE 17.0 8.5

This estimate does not include the task-hour data given in the service bulletins in Paragraph 1.B.,

Concurrent Requirements.

H. Weight and Balance Changes

None.

I. Electrical Load Data

Not applicable.

J. References

1. Existing Data:

a. Engineering Change Memo PRR 85901-009SK

b. Service Related Problem (SRP)s 747-SRP-53-0129 and 747-SRP-53-0232

c. 747-100/200/300 Aircraft Maintenance Manual (AMM) 20-30-08, 25-21-03, 25-21-04, 51-21-01,

51-21-02, 51-31-01, 52-09-02, 52-11-07, 53-21-02

d. 747-400 Aircraft Maintenance Manual (AMM) 20-30-08, 25-21-03, 25-21-04, 51-21-01,

51-21-02, 51-31-01, 52-09-02, 52-11-07, 53-21-02

e. 747-100/200/300 Structural Repair Manual (SRM) 51-10-02, 51-30-02

f. 747-400 Structural Repair Manual (SRM) 51-20-01, 51-40-02

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BOEING SERVICE BULLETIN 747-53-2460
g. Standard Overhaul Practices Manual (SOPM) 20-10-03 , 20-20-02, 20-30-02 , 20-41-02,

20-43-03 , 20-50-10 , 20-50-19

h. Boeing Service Bulletin 747-53A2378 "FUSELAGE-Main Deck Door-Mounted Escape Slide

Grit Bar Fittings Inspection, Repair, or Replacement"

i. Federal Aviation Administration (FAA) Airworthiness Directive 2007-12-11, 2008-18-07

j. FAA Notice of Proposed Rule Making, FAA Docket Number 2002-NM-285-AD, issued July

13, 2004

k. Boeing Parts Standards Document D-590

l. Boeing Drawing 65B88700

m. Engineering Change Memo PRR 85901-60RS

2. Data supplied with this Service Bulletin:

None.

3. Installation Drawings Used in the Preparation of this Service Bulletin:

Drawing Number Title

65B01843 Forward Frame Instl - No. 3 Entry Door Panel STA 1265

65B01893 Sill Installation - Lower Main No. 3 Entry Door Panel

65B08208 Reveal Installation - No. 3 Main Entry Door

65B10440 Seal Application Instl - Skin Area, Sect. 44 Lower

65B50397 Doorway Lining Installation - No. 3 Doorway

411U2223 Lining Instl - Entry Way, Door 3

These drawings were used to prepare this service bulletin. These drawings are not necessary to

make the specified changes, and are not supplied with this service bulletin. These drawings may

not be applicable to all airplane configurations or operators.

K. Publications Affected

1. Publications

Publication Chapter-Section

747 Illustrated Parts Catalog 53-12

2. Damage Tolerance Based Structural Inspections:

Boeing has evaluated the repairs and/or changes in this service bulletin for effects on Fatigue

Critical Structure (FCS) and for changes to Damage Tolerance Inspections (DTI) required in the

Maintenance Program. This service bulletin affects FCS but no new DTIs are necessary.

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BOEING SERVICE BULLETIN 747-53-2460
L. Interchangeability and Intermixability of Parts

Refer to Paragraph 2.C., Parts Necessary for Each Airplane, for interchangeability and intermixability

information.

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BOEING SERVICE BULLETIN 747-53-2460
2. MATERIAL INFORMATION

A. Material - Price and Availability

Boeing can supply the kits shown in Paragraph 2.C., Parts Necessary for Each Airplane. Operators

are encouraged to share schedule requirements with Boeing for incorporation of the service bulletin.

The kits are subject to the terms and conditions of the Boeing standard purchase order acknowledgment.

Prices are in United States Dollars. Terms: Net 30 days.

Reference this service bulletin and submit your purchase order by one of these methods:

1. Order on-line via ATA Spec 2000 or The Boeing PART Page

2. Fax to (206) 662-7145

REFER TO THE BOEING PART PAGE ON MYBOEINGFLEET.COM OR CONTACT FIRST RESPONDER

AT FR@BOEING.COM FOR THE LATEST REORDER LEAD TIME (ROLT) AND PRICE INFORMATION

Unit Price as of

May 31, 2006 (US

Dollars)

ROLT as of May

31, 2006 (Calendar Days)

Kit Number Name

015U1697-1 Top Kit Inactive for procurement

015U1787-1 Top Kit 35 $9,298

015U1787-2 Kit 35 $227

B. Industry Support Information

Boeing warranty remedies are not available for the inspections and repair procedures given in this

service bulletin.

C. Parts Necessary For Each Airplane

1. Kits/Parts:

To get the kits/parts shown below, refer to Paragraph 2.A., Material - Price and Availability.

One top kit and the items shown in Paragraph 2.C.2., Parts and Materials Supplied by the Operator,

are necessary for each airplane.

If an operator has previously obtained Top Kit 015U1697-1, the 65B11751-605 and 65B11751-606

Reveal Assemblies in that kit can be reworked into the required 65B11751-5 and 65B11751-6

Reveal Assemblies as given in Figures 14 and 15 of this service bulletin.

Kit 015U1787

Existing Part Notes

Number

New Part Number QTY Name

-2 -1

015U1787-1 . - Top Kit (a)

015U1787-2 - 2 Fastener Kit (b) (c) (d)

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BOEING SERVICE BULLETIN 747-53-2460
Kit 015U1787

Existing Part Notes

Number

New Part Number QTY Name

-2 -1

65B11751-601 or (e) (f) (g)

65B11751-605

65B11751-5 (65B11751- . 1 REVEAL ASSY

11 Optional)

65B11751-602 or (e) (f) (g)

65B11751-606

65B11751-6(65B11751- . 1 REVEAL ASSY

12 Optional)

BACB30NN3K9 2 . BOLT

BACB30NX6K3Y 3 . BOLT

BACB30NX8K3 11 . BOLT

BACB30NX8K4X 4 . BOLT

BACB30NY6K16X 3 . BOLT

BACB30NY6K16Y 3 . BOLT

BACB30NY6K17X 3 . BOLT

BACB30NY6K17Y 3 . BOLT

BACB30NY6K3Y 1 . BOLT

BACB30NY8K16X 1 . BOLT

BACB30NY8K16Y 1 . BOLT

BACB30NY8K3 1 . BOLT

BACB30VF3K3 2 . BOLT

BACC30AC6 1 . COLLAR

BACC30BH8 14 . COLLAR

BACC30R6 3 . COLLAR

BACN10JN3 7 . NUT PLATE

BACN10JR3 2 . NUTPLATE

BACN10JZ3B2 3 . NUT PLATE

BACN10YR3CD 2 . NUT

BACN10YT3CD 3 . NUT

BACN10YT4CD 1 . NUT

BACR15GF3D4 18 . RIVET

BACS40R011C044F 1 . SHIM, LAMINATED

(BACS40R011C045Foptional)

BACW10BP31DP 15 . WASHER, PLAIN

BACW10BP32DP 15 . WASHER, PLAIN

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BOEING SERVICE BULLETIN 747-53-2460
Kit 015U1787

Existing Part Notes

Number

New Part Number QTY Name

-2 -1

NAS1149D0363J 2 . WASHER, FLAT

NAS1399D4A4 6 . RIVET

(a) Replacement Top Kit. Replaces original Top Kit 015U1697-1.

(b) On Group 2 and 3 airplanes, if the inspection in this service bulletin shows that the existing corner reveal assemblies are not cracked, the existing reveal assemblies can be

reworked into the required 65B11751-5 and 65B11751-6 Reveal Assemblies. Only

Fastener Kits 015U1787-2 (one for each side of the airplane) would then be required.

(c) There are more parts than are necessary.

(d) If grip length shown is not available at Boeing, fasteners supplied in kits may be one

grip length longer than indicated. Also, if any fasteners part numbers listed are not

available or have been superseded, substitute fasteners may be supplied in kits. Boeing

Document D-590 and Boeing Drawing 65B88700 are used to determine the part numbers

used as substitutes.

(e) Discard the existing part.

(f) This part is used in production.

(g) You cannot use the existing part to replace the new or changed part.

Kit 65B11751

Existing Part Notes

Number

New Part Number QTY Name

-12 -11 -6 -5

65B11751-5 . . . - REVEAL ASSY

65B11751-6 . . - . REVEAL ASSY

65B11751-11 . - . . REVEAL ASSY

65B11751-12 - . . . REVEAL ASSY

65B11751-1 . . . 1 REVEAL

65B11751-2 . . 1 . REVEAL

65B11751-3 . . . 1 REVEAL

65B11751-4 . . 1 . REVEAL

65B11751-7 . 1 . . REVEAL

65B11751-8 1 . . . REVEAL

65B11751-9 . 1 . . REVEAL

65B11751-10 1 . . . REVEAL

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BOEING SERVICE BULLETIN 747-53-2460
Kit 015U1697

Existing Part Notes

Number

New Part Number QTY Name

-3 -2 -1

015U1697-1 . . - Top Kit (d)

015U1697-2 . - 1 Subkit - Door 3 Left (b) (c)

015U1697-3 - . 1 Subkit - Door 3 Right (b) (c)

65B11751-605 . 1 . Corner Reveal 65B11751-601 (a)

65B11751-606 1 . . Corner Reveal 65B11751-602 (a)

BACB30NX6K3Y 3 3 . Bolt

BACB30NX8K3 11 11 . Bolt

BACB30NX8K4X 2 2 . Bolt

BACB30NN3K9 2 2 . Bolt

BACB30NY6K16X 3 3 . Bolt

BACB30NY6K16Y 3 3 . Bolt

BACB30NY6K17X 3 3 . Bolt

BACB30NY6K17Y 3 3 . Bolt

BACB30NY6K3Y 1 1 . Bolt

BACB30NY8K16X 1 1 . Bolt

BACB30NY8K3 1 1 . Bolt

BACB30VF3K3 2 2 . Bolt

BACB30NY8K16Y 1 1 . Bolt

BACB30NX8K4X 2 2 . Bolt

BACC30AC6 1 1 . Collar

BACC30BH8 14 14 . Collar

BACC30R6 3 3 . Collar

BACN10JN3 7 7 . Nutplate

BACN10JR3 2 2 . Nutplate

BACN10YR3CD 2 2 . Nut

BACN10JZ3B2 3 3 . Nutplate

BACN10YT3CD 3 3 . Nut

BACN10YT4CD 1 1 . Nut

BACR15GF3D4 18 18 . Rivet

BACS40R011C044F 1 1 . Shim

BACW10BP31DP 15 15 . Washer

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BOEING SERVICE BULLETIN 747-53-2460
Kit 015U1697

Existing Part Notes

Number

New Part Number QTY Name

-3 -2 -1

BACW10BP32DP 15 15 . Washer

NAS1149D0363J 2 2 . Washer

NAS1399D4A4 6 6 Rivet

(a) You cannot use the existing part to replace the new or changed part.

(b) The Subkits contain more fasteners than are necessary to accomplish this service bulletin.

(c) If grip length of fasteners shown in the Subkits are not available at Boeing, fasteners

supplied in kits may be one grip length longer than indicated. Also, if any fasteners part

numbers listed are not available or have been superseded, substitute fasteners may be

supplied in kits. Boeing Document D-590 and Boeing Drawing 65B88700 are used to

determine the part numbers used as substitutes.

(d) Superseded by Top Kit 015U1787-1.

2. Parts and Materials Supplied by the Operator:

Part Number / Specifi- QTY Name Notes

cation

BMS 5-142 (a) 4 Ounces Sealant -

BMS 5-95 (a) 1 Quart Sealant -

BMS 10-11 Type 1 (a) 4 Ounces Primer -

BMS 10-60 Type 1 (a) 4 Ounces Enamel Color 702 White

Order Class B1 for 1 hour cure time or

Class B1/4 for 15 minute cure time.

EC-3587-B/A (b) 1 Pint Fairing Compound

Corrosion Preventive -

Compound

MIL-C-11796 Class 3 1 Ounce

AC962-73C (c) 4 Ounces Parting Agent -

(a) See the Qualified Products List at the end of the Boeing Material Specification (BMS) for supplier

data.

(b) 3M, 3211 E. Chestnut Express Way Springfield Missouri 65802 USA, Phone 417 869-4235, Fax

417-869-5219

(c) AC Products, Inc. 172 East La Jolla Street, Palencia, California 92870 Phone: 714-630-7311

3. Parts Modified and Reidentified:

None.

4. Parts Removed and Not Replaced:

None.

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BOEING SERVICE BULLETIN 747-53-2460
D. Parts Necessary to Change Spares

None.

E. Special Tooling - Price and Availability

None.

F. Special Tooling Necessary to do this Service Bulletin

No special tools or equipment are necessary to do the change in this service bulletin. But, maintenance

and overhaul tools in the manuals given in Paragraph 1.J., References, can be necessary. Examine

operator tool supply to make sure all necessary tools are available.

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BOEING SERVICE BULLETIN 747-53-2460
3. ACCOMPLISHMENT INSTRUCTIONS

A. GENERAL INFORMATION

CAUTION: KEEP THE WORK AREA, WIRES AND ELECTRICAL BUNDLES CLEAN OF METAL

PARTICLES OR CONTAMINATION WHEN YOU USE TOOLS. UNWANTED MATERIAL,

METAL PARTICLES OR CONTAMINATION CAUGHT IN WIRE BUNDLES CAN CAUSE

DAMAGE TO THE BUNDLES. DAMAGED WIRE BUNDLES CAN CAUSE SPARKS OR

OTHER ELECTRICAL DAMAGE.

NOTE: 1. The instructions identified in Paragraph 3.B. Work Instructions and the Figures(s)

give the recommended sequence of steps. The sequence of steps to do this service

bulletin can be changed.

2. Manual titles are referred to by acronyms. Refer to Paragraph 1.J., References, for

definition of the acronyms.

3. Obey all of the warnings and cautions given in the specified manual sections.

4. Unless shown differently, these dimensions and tolerances are used:

— Linear dimensions are in inches

— Tolerance on linear dimensions, other than rivet and bolt edge margins, is plus

or minus 0.03 inch.

— Tolerance on rivet and bolt edge margin is plus or minus 0.05 inch

— Angular tolerance is plus or minus 2 degrees

— Hole dimensions for standard solid rivets are given in Chapter 51 of the applicable

SRM

— Torque limits to tighten nuts and bolts are given in Chapter 51 of the applicable

SRM

5. If the length of any fastener specified in this service bulletin does not meet the

installation standards in Chapter 51 of the applicable SRM, then a fastener of the

same specification, or an approved substitute, with a length which meets the

installation standards in Chapter 51 of the applicable SRM may be used.

6. Use the approved fastener and process material substitutions in accordance with

Chapter 51 of the applicable SRM. Alternate fasteners are listed in Chapter 51 of

the applicable SRM and Boeing Drawing 012W6100.

7. A General Visual Inspection is defined as: A visual examination of an interior or

exterior area, installation or assembly to detect obvious damage, failure or irregularity.

This level of inspection is made from within touching distance unless otherwise

specified. A mirror may be necessary to ensure visual access to all surfaces in the

inspection area. This level of inspection is made under normal available lighting

conditions such as daylight, hangar lighting, flashlight or drop-light and may require

removal or opening of access panels or doors. Stands, ladders or platforms may be

required to gain proximity to the area being checked.

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BOEING SERVICE BULLETIN 747-53-2460
8. A Detailed Inspection is defined as: An intensive examination of a specific item,

installation, or assembly to detect damage, failure, or irregularity. Available lighting

is normally supplemented with a direct source of good lighting at an intensity deemed

appropriate. Inspection aids such as mirrors magnifying lenses, etc. may be

necessary. Surface cleaning and elaborate procedures may be required.

9. Deleted

10. These work instructions refer to procedures included on other Boeing documents.

When the words "refer to" are used and the operator has an accepted alternative

procedure, the accepted alternative procedure can be used. When the words "in

accordance with" are included in the instruction, the procedure in the Boeing document

must be used.

11. Refer to Appendix A for the procedure for the Door 3 lower forward corner reveal

material type inspection.

12. Where the work instructions include installation of a kept part, a new or serviceable

part with the same part number can be installed as an alternative to the kept part.

The removed part can be discarded if a new or serviceable part is installed.

B. WORK INSTRUCTIONS

PART 1 - INSPECTION FOR ONE-PIECE OR TWO-PIECE CORNER REVEALS

1. Gain access to the left and right Door 3 lower forward corner reveals. Refer to FIGURE 2 as an

accepted procedure.

2. Do a general visual inspection in accordance with FIGURE 17 to determine if the installed lower

forward corner reveals are one-piece or two-piece corner reveals.

3. At any one-piece corner reveal that is found, do one of the following:

Group 1, Configuration 2; Group 2, 4:

a. Do a detailed inspection of any one-piece corner reveal for a sharp edge detail in accordance

with FIGURE 11.

(1) If no sharp edge detail is found, do a detailed inspection of the corner reveal for cracks

in accordance with PART 2.

(2) If a sharp edge detail is found, rework the reveal in accordance with FIGURE 12 to remove

the sharp edge. After rework to remove the sharp edge, do a detailed inspection of the

corner reveal for cracks in accordance with PART 2.

b. Replace the lower forward corner reveal with a new 2-piece corner reveal as given in PART

3. No further inspections are necessary after the two-piece corner reveal is installed.

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Group 1, Configuration 1; Group 3:

a. Do a detailed inspection of any one-piece corner reveal for cracks in accordance with PART

2.

b. Replace the lower forward corner reveal with a new 2-piece corner reveal as given in PART

3. No further inspections are necessary after the two-piece corner reveal is installed.

PART 2 - INSPECTION OF ONE-PIECE CORNER REVEALS FOR CRACKS

1. Inspect any installed one-piece corner reveal for cracks in accordance with FIGURE 3.

2. If no cracks are found, restore access. Refer to FIGURE 2 as an accepted procedure. Put the

airplane back to a serviceable condition and continue to do repeat inspections of one-piece corner

reveals in accordance with Paragraph 1.E., Compliance.

NOTE: As an alternative to repeated inspections, replace the corner reveal with a two-piece

corner reveal as given in PART 3. No further inspections are necessary after the two-piece

corner reveal is installed.

3. If cracks are found, do one of the following:

a. Replace the corner reveal with a two-piece corner reveal in accordance with PART 3. No

further inspections are necessary after the two-piece corner reveal is installed.

b. Group 1, Configuration 1; Group 4:

If the material type inspection in FIGURE 4 determines that the reveal is a casting, do the

weld repair in accordance with PART 4. After repair, continue to do inspections of the repaired

corner reveal in accordance with Paragraph 1.E., Compliance.

PART 3 - TWO-PIECE LOWER FORWARD CORNER REVEAL INSTALLATION

1. Gain additional access to the door corner reveal. Refer to FIGURE 5 as an accepted procedure.

2. Remove the corner reveal in accordance with FIGURE 9.

NOTE: Uncracked, one-piece 6061 aluminum corner reveals that do not have a sharp edge detail

can be reworked into two-piece corner reveals in accordance with PART 5.

3. Install the two-piece corner reveal in accordance with FIGURE 10.

4. Restore access. Refer to FIGURE 2 and FIGURE 5 as accepted procedures.

5. Adjust and test the girt bar mechanism. Refer to the task "Girt Mechanism Adjustment and Test"

in 747-100/200/300 AMM 52-11-07 or 747-400 AMM 52-11-07 as an accepted procedure.

6. Put the airplane back to a serviceable condition.

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Group 1, Configuration 1; Group 4:

PART 4 - CAST ALUMINUM CORNER REVEAL WELD REPAIR

1. Gain additional access to the corner reveal. Refer to FIGURE 5 as an accepted procedure.

2. Remove the Door Corner Reveal in accordance with FIGURE 7.

NOTE: The weld repair given in the following step is only applicable to cast aluminum corner

reveals.

3. Do the Weld Repair on the Door Corner Reveal in accordance with FIGURE 8.

4. Install the Repaired Door Corner Reveal in accordance with FIGURE 7.

5. Restore access. Refer to FIGURE 2 and FIGURE 5 as accepted procedures.

6. Adjust and test the girt bar mechanism. Refer to the task "Girt Mechanism Adjustment and Test"

in 747-100/200/300 AMM 52-11-07 or 747-400 AMM 52-11-07 as an accepted procedure.

7. Put the airplane back to a serviceable condition.

PART 5 - REWORK OF A ONE-PIECE CORNER REVEAL INTO A TWO-PIECE CORNER REVEAL

1. Gain additional access to the corner reveal. Refer to FIGURE 5 as an accepted procedure.

2. Remove the corner reveal in accordance with FIGURE 9.

NOTE: Only uncracked, one-piece 6061 aluminum corner reveals that do not have a sharp edge

detail can be reworked into two-piece corner reveals in accordance with PART 5. Do not

rework one-piece cast aluminum fittings. FIGURE 4 includes a procedure to identify corner

reveal material types.

3. Rework the left side corner reveal into a 2-piece corner reveal in accordance with FIGURE 13.

4. Rework the right side corner reveal into a 2-piece corner reveal in accordance with FIGURE 14.

Group 1, Configuration 1; Group 4:

PART 6 - MATERIAL TYPE INSPECTION

1. Gain access to the affected (left and/or right) Door 3 lower forward corner reveals. Refer to FIGURE

2 as an accepted procedure.

2. Do the material type inspection in accordance with FIGURE 4 to determine if the corner reveal is

a casting.

3. If the material type inspection determines that the corner reveal is a casting, replace the cast reveal

with a two-piece machined aluminum reveal in accordance with Paragraph 1.E., Compliance.

4. If the material type inspection determines that the corner reveal is not a casting, continue to do

inspections or replace with a two-piece machined reveal in accordance with Paragraph 1.E.,

Compliance. Restore access. Refer to FIGURE 2 as an accepted procedure. Put the airplane back

to a serviceable condition.

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FIGURE 1: LOGIC DIAGRAM

(SHEET 1 OF 1)

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FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION

(SHEET 1 OF 7)

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FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION

(SHEET 2 OF 7)

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FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION

(SHEET 3 OF 7)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION

(SHEET 4 OF 7)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

ACCESS

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

Doorway Scuff - 1

Plate

1 Remove / Keep

Fasteners - 12

Keep Fasteners. Refer to

747-100/200/300 AMM

25-21-03 or 747-400

AMM 25-21-03 as an accepted procedure.

Forward Corner - 1

Scuff Plate

2 Remove / Keep

Fasteners - 7

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

Aft Corner Scuff - 1

Plate

3 Remove / Keep

Fasteners - 5

4 Remove / Keep Fasteners - 39

Threshold - 1

Clean Sealant from Doorway Scuff Plate, Fwd and

Aft Scuff Plates, Threshold and Structure. Refer

to 747-100/200/300 AMM

25-21-03 or 747-400

AMM 25-21-03 as an accepted procedure.

5 Clean Sealant - -

RESTORATION

Fay Surface Seal with

BMS 5-95 Sealant. See

Flagnotes 1, 2 and 3.

6 Install / Kept Threshold - 1

Install with BMS 5-95

Sealant under Bolt Head.

Use Protection Sealant

Method 1 as given in

SOPM 20-50-19 as an

accepted procedure.

Fasteners - 39

FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION

(SHEET 5 OF 7)

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STEP TASK NAME PART NUMBER QTY NOTES

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

Aft Corner Scuff - 1

Plates

7 Install / Kept

Install with BMS 5-95

Sealant under Bolt Head.

Use Protection Sealant

Method 1 as given in

SOPM 20-50-19 as an

accepted procedure.

Fasteners - 5

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

Fwd Corner Scuff - 1

Plates

8 Install / Kept

Install with BMS 5-95

Sealant under Bolt Head.

Use Protection Sealant

Method 1 as given in

SOPM 20-50-19 as an

accepted procedure.

Fasteners - 7

Fay Surface Seal with

BMS 5-95 Sealant. Refer

to 747-100/200/300 AMM

25-21-03 or 747-400

AMM 25-21-03 as an accepted procedure. See

Flagnote 3.

Doorway Scuff - 1

Plate

9 Install / Kept

Install with BMS 5-95

Sealant under Bolt Head.

Use Protection Sealant

Method 1 as given in

SOPM 20-50-19 as an

accepted procedure.

Install / Kept Fasteners - 12

Fillet seal edges of Corner Scuff Plates with BMS

5-95. Refer to 747-

100/200/300 AMM 25-21-

03 or 747-400 AMM 25-

21-03 as an accepted

procedure.

10 Install Fillet Seal - 1

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION

(SHEET 6 OF 7)

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FLAG NAME PART NUMBER QTY NOTES

NOTE

Prepack cavity with sealant. Use the removable

faying surface seal application method. Refer to

747-100/200/300 AMM 51-31-01 or 747-400 AMM

51-31-01 as an accepted procedure.

1 Parting Agent AC962-73C -

Sealant BMS 5-95 -

Fay Surface Seal. Use the removable faying surface seal application method. Refer to 747-

100/200/300 AMM 51-31-01 or 747-400 AMM 51-

31-01 as an accepted procedure.

2 Parting Agent AC962-73C -

Sealant BMS 5-95 -

Apply a bead of sealant 0.17 - 0.23 inches high

by 0.17 - 0.23 inches wide under the Threshold.

Use BMS 5-95. Do not block the Drain Holes.

Refer to 747-100/200/300 AMM 51-31-01 or 747-

400 AMM 51-31-01 as an accepted procedure.

Drain Sealant BMS 5-95 -

Bead

3

Fay Surface Seal the joint between Door Scuff

Plate and Threshold and joint between the Door

Scuff Plate and Corner Scuff Plates. Use the removable faying surface seal application method.

Refer to 747-100/200/300 AMM 51-31-01 or 747-

400 AMM 51-31-01 as an accepted procedure.

4 Parting Agent AC962-73C -

Sealant BMS 5-95 -

FIGURE 2: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL INSPECTION

(SHEET 7 OF 7)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 3: DOOR CORNER REVEAL - INSPECTION FOR CRACKS

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

Do a Detailed Inspection

for cracks. Inspect the

upper and lower surface

of the Corner Reveal.

65B11751-601 1

(Left)

1 Inspect Corner Reveal

65B11751-602 1

(Right)

FIGURE 3: DOOR CORNER REVEAL - INSPECTION FOR CRACKS

(SHEET 2 OF 2)

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FIGURE 4: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION

(SHEET 1 OF 2)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

Refer to 747-100/200/300 AMM

51-21-01 or 747-400 AMM 51-21-

01 as an accepted procedure.

1 Remove Finish - -

65B11751-601 or 1 See APPENDIX A

65B11751-605 (Left)

2 Inspect Corner Reveal

65B11751-602 or 1

65B11751-606 (Right)

Restore finish to the Corner Reveal. Alodine and apply 1 coat of

BMS 10-11 Type 1 Primer. Refer

to 747-100/200/300 SRM 51-10-

02, 747-400 SRM 51-20-01, and

SOPM 20-41-02 or as an accepted

procedure.

3 Apply Finish - -

FIGURE 4: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

STEP TASK NAME PART NUMBER QTY NOTES

ACCESS

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

1 Remove / Keep Dado Panel - 1

FIGURE 5: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL REMOVAL AND INSTALLATION

(SHEET 1 OF 2)

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STEP TASK NAME PART NUMBER QTY NOTES

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

Doorway Side Lin- - 1

ing

2 Remove / Keep

Refer to 747-100/200/300

AMM 53-21-02 or 747-

400 AMM 53-21-02 as an

accepted procedure.

3 Remove / Keep Floor Panels - -

Refer to 747-100/200/300

AMM 25-21-04 or 747-

400 AMM 25-21-04 as an

accepted procedure.

4 Remove / Keep Insulation - 1

RESTORATION

Refer to 747-100/200/300

AMM 25-21-04 or 747-

400 AMM 25-21-04 as an

accepted procedure.

5 Install / Kept lnsulation - 1

Refer to 747-100/200/300

AMM 53-21-02 or 747-

400 AMM 53-21-02 as an

accepted procedure.

6 Install / Kept Floor Panels - -

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

Doorway Side Lin- - 1

ing

7 Install / Kept

Refer to 747-100/200/300

AMM 25-21-03 or 747-

400 AMM 25-21-03 as an

accepted procedure.

8 Install / Kept Dado Panel - 1

FIGURE 5: ACCESS AND RESTORATION FOR DOOR CORNER REVEAL REMOVAL AND INSTALLATION

(SHEET 2 OF 2)

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FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 1 OF 9)

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FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 2 OF 9)

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FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 3 OF 9)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each side of the airplane.

FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 4 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Fasteners - 2 -

Remove / Keep Girt Bar Fitting - 1 -

Remove / Keep Plate - 1 -

2 Remove / Discard Fasteners - 2 -

3 Remove / Discard Fasteners - 18 -

Remove / Discard Corner Reveal 65B11751-601 (left) 1 See Flagnote 1

65B11751-602 (right) 1

Shim - 1 Remove if installed.

4 Remove / Discard Nutplates - 2 -

From the structure. Refer to

747-100/200/300 AMM 20-

30-08 or 747-400 AMM 20-

30-08 as an accepted procedure.

5 Clean Sealant - -

6 Position Corner Reveal 65B11751-605 (left) 1 (a)

65B11751-606 (right) 1

Shim BACS40R011C044F 1 If required. See Flagnote 2

7 Back Drill Holes - 22 -

Temporary Fasten- - 4 -

ers

8 Install

9 Position Kept Threshold - 1 Removed in Figure 2.

10 Back Drill Holes 0.190 - 0.199 3

Doorway Scuff - 1 Removed in Figure 2.

Plate

11 Position Kept

12 Back Drill Holes 0.190 - 0.199 1 at nutplate location.

13 Position Kept Forward - 1 Removed in Figure 2.

Corner Scuff Plate

14 Back Drill Holes 0.190 - 0.199 3 at nutplate locations.

15 Remove / Keep Corner Scuff Plate 1 -

Doorway Scuff - 1 -

Plate

16 Remove / Keep

17 Remove / Keep Threshold - 1 -

FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 5 OF 9)

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STEP TASK NAME PART NUMBER QTY NOTES

Temporary Fasten- - 4 -

ers

18 Remove / Discard

Remove / Keep Corner Reveal 65B11751-605 (left) 1 -

65B11751-606 (right) 1 -

Shim BACS40R011C044F 1 -

19 Position Nutplates - 7 -

20 Back Drill Holes - 14 -

21 Clean / Debur Holes - - All drilled holes.

Install rivets wet with BMS 5-

95 Sealant.

22 Install Nut Plates BACN10JZ3B2 2

23 Install Nut Plates - 7 -

Install with Fay Surface

Sealant. See Flagnote 3.

24 Install / Kept Corner Reveal 65B11751-605 (left) 1

65B11751-606 (right) 1

Shim BACS40R011C044F 1 If required. See Flagnote 2

Install wet with BMS 5-95

Sealant. See Flagnote 4.

Install Fasteners - 20

25 Apply Fairing Compound EC-3587-B/A - See Flagnote 5 and 6.

Apply over Fairing Compound. Refer to SOPM 20-

41-02 as an accepted procedure.

26 Apply Primer BMS 10-11 Type 1 -

Boeing Color 702 White Refer to 747-100/200/300 AMM

51-21-02 or 747-400 AMM

51-21-02 as an accepted

procedure.

27 Apply Enamel BMS 10-60 Type 1

Install wet with BMS5-95

Sealant.

28 Install Fasteners - 2

Install with Fay Surface

Sealant. See Flagnote 7.

29 Install / Kept Plate - 1

Girt Bar Fitting - 1 -

Install with MIL-C-11796,

Class 3 corrosion preventive

compound to all areas of the

hole and on the fasteners.

Install Fasteners BACB30NN3K9 2

(a) Prior to installation of the new corner reveal, do an inspection for a sharp edge detail as given in Part 1

of the Accomplishment Instructions. Rework the reveal to remove the sharp edge as shown in Part 1 of

FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 6 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

the Accomplishment Instructions if necessary. Do not install a reveal which has the sharp edge detail

described in Part 1 of the Accomplishment Instructions.

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME PART NUMBER QTY NOTES

NOTE

Some airplanes may have the nutplates attach

with rivets that go through the Corner Reveal and

the bracket below. For this configuration the nutplate attach rivets must be removed before the

Corner Reveal can be removed.

1 Fasteners - 4

Install Shim as required to maintain a maximum

gap of 0.010 gap. Finish with BMS 10-11 Type 1

Primer after delaminations are removed. Shim can

be installed with the primer wet or dry. Refer to

SOPM 20-41-02 as an accepted procedure.

2 Shim - 1

Apply fay surface seal between Outboard side of

Corner Reveal and Skin strap. Refer to 747-

100/200/300 AMM 51-31-01 or 747-400 AMM 51-

31-01 747-400 AMM 51-31-01 as an accepted

procedure.

3 Fay Surface Seal BMS 5-95 -

Grinding off the end of Bolt is allowed. Grind so

that end of bolt is even with the surface of the

Corner Reveal. Do not grind the nut.

4 Grind Bolt -

Make a seal ramp between the Corner Reveal and

Door Frame. Grind Compound to match contour

of seal plane. Grind smooth to touch (125 microinches or less) fill small voids with BMS 5-142.

Do the Air Leak and Seal Contact Surface Inspection to verify the seal contact on the seal ramp.

Refer to SOPM 20-50-19 and 747-100/200/300

AMM 52-09-02 or 747-400 AMM 52-09-02 as an

accepted procedure.

5 Fairing Compound - -

Fill Fastener Holes with Fairing Compound. For

fastener holes that are not under the seal ramp,

grind flush with the Revel.

6 Fairing Compound - -

Apply fay surface seal between Plate and Corner

Reveal. Refer to 747-100/200/300 AMM 51-31-01

or 747-400 AMM 51-31-01 747-400 AMM 51-31-

01 as an accepted procedure.

7 Fay Surface Seal BMS 5-95 -

FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 7 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65B88700 are used to

determine the part numbers used as substitutes.

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NN3K9 0.190 - 0.194

0.1890 -

0.1905

B Bolt BACB30VF3K3

Washer NAS1149D0363J

Nut BACN10YR3CD

C Rivet NAS1399D4A4 0.129 - 0.132

0.2021 -

0.2036

D Bolt (a) BACB30NY6K16X

0.2021 -

0.2036

Bolt (a) BACB30NY6K17X

Nut BACN10JC3CD

0.2177 -

0.2192

Bolt (a) BACB30NY6K16Y

0.2177 -

0.2192

Bolt (a) BACB30NY6K17Y

FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 8 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
CODE NAME PART NUMBER HOLE DIA NOTES

0.2646 -

0.2661

E Bolt (b) BACB30NY8K16X

0.2802-

0.2817

Bolt (b) BACB30NY8K16Y

Nut BACN10YT4CD

F Bolt (c) BACB30NX6K3Y 0.216 - 0.219

Collar (c) BACC30R6

Bolt (c) BACB30NX8K3 0.247 - 0.250

Collar (c) BACC30BH8

G Bolt (d) BACB30NY6K3Y 0.216 - 0.219

Collar (d) BACC30AC6

Bolt (d) BACB30NW8K3 0.247 - 0.250

Collar (d) BACC30BL8

H Bolt BACB30NX8K3 0.247 - 0.250

Collar BACC30BH8

I Bolt BACB30NX8K4X 0.263 - 0.266

Collar BACC30BH8

J Nutplate BACN10JN3

K Nutplate BACN10JR3

L Rivet BACR15GF3D4 0.098 - 0.103

(a) Bolts of 2 diameters and 2 grip lengths are included in the kit. Use the smallest hole diameter that

will produce a clean hole. Use the appropriate grip length bolt. Refer to 747-100/200/300 SRM 51-

30-02 or 747-400 SRM 51-40-02.

(b) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean

hole. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

(c) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean

hole. Use the BACC30R6 Collar with the BACB30NX6K3Y Bolt. Use the BACC30BH8 Collar with

the BACB30NX8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

(d) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean

hole. Use the BACC30AC6 Collar with the BACB30NY6K3Y Bolt. Use the BACC30BL8 Collar with

the BACB30NW8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

FIGURE 6: ONE-PIECE DOOR CORNER REVEAL - REPLACEMENT

(SHEET 9 OF 9)

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FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 1 OF 8)

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FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 2 OF 8)

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BOEING SERVICE BULLETIN 747-53-2460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each side of the airplane.

FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 3 OF 8)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Fasteners - 2 -

Remove / Keep Girt Bar Fitting - 1 -

Remove / Keep Plate - 1 -

2 Remove / Discard Fasteners - 2 -

3 Remove / Discard Fasteners - 18 -

Remove / Keep Corner Reveal 65B11751-601 (left) 1 See Flagnote 1

65B11751-602 (right) 1

Remove / Discard Shim - 1 If installed.

4 Remove / Discard Nutplates - 9

From the structure and

the Corner Reveal. Refer

to 747-100/200/300 AMM

20-30-08 and 747-400

AMM 20-30-08 as an accepted procedure.

5 Clean Sealant - -

AFTER WELD REPAIR

6 Position / Kept Corner Reveal 65B11751-601 (left) 1 -

65B11751-602 (right) 1 -

If required. See Flagnote

2

Shim BACS40R011C044F 1

7 Back Drill Holes - 22 -

8 Remove / Keep Corner Reveal 65B11751-601 (left) 1 -

65B11751-602 (right) 1 -

Shim BACS40R011C044F 1 -

9 Clean / Debur Holes - - All drilled holes.

10 Install Nutplates - 7 -

Install rivets wet with

BMS 5-95 Sealant.

11 Install Nut Plates BACN10JZ3B2 2

Install with Fay Surface

Sealant. See Flagnote 3.

12 Install / Kept Corner Reveal 65B11751-601 (left) 1

65B11751-602 (right) 1 -

If required. See Flagnote

2

Install Shim BACS40R011C044F 1

Install wet with BMS 5-95

Sealant. See Flagnote 4

Fasteners - 20

FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 4 OF 8)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

13 Apply Fairing Compound EC-3587-B/A - See Flagnotes 5 and 6

Apply over Fairing Compound. Refer to SOPM

20-41-02 SOPM 20-41-02

as an accepted procedure.

14 Apply Primer BMS 10-11 Type 1 -

Boeing Color 702 White

Refer to 747-100/200/300

AMM 51-21-02 or 747-

400 AMM 51-21-02 as an

accepted procedure.

15 Apply Enamel BMS 10-60 Type 1

Install wet with BMS5-95

Sealant.

16 Install Fasteners - 2

Install with Fay Surface

Sealant. See Flagnote 7.

17 Install / Kept Plate - 1

Girt Bar Fitting - 1 -

Install with MIL-C-11796,

Class 3 corrosion preventive compound to all areas of the hole and on the

fasteners.

Install Fasteners BACB30NN3K9 2

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FLAG NAME PART NUMBER QTY NOTES

NOTE

Some airplanes may have the nutplates attach

with rivets that go through the Corner Reveal and

the bracket below. For this configuration the nutplate attach rivets must be removed before the

Corner Reveal can be removed.

1 Fasteners - 4

Install Shim as required to maintain a maximum

gap of 0.010 gap. Finish with BMS 10-11 Type 1

Primer after delaminations are removed. Shim can

be install with the primer wet or dry. Refer to

SOPM 20-41-02 as an accepted procedure.

2 Shim - 1

Apply fay surface seal between Outboard side of

Corner Reveal and Skin strap. Refer to 747-

100/200/300 AMM 51-31-01 or 747-400 AMM 51-

31-01 as an accepted procedure.

3 Fay Surface Seal BMS 5-95 -

FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 5 OF 8)

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FLAG NAME PART NUMBER QTY NOTES

NOTE

Grinding off the end of Bolt is allowed. Grind so

that end of bolt is even with the surface of the

Corner Reveal. Do not grind the nut.

4 Grind Bolt -

Make a seal ramp between the Corner Reveal and

Door Frame. Grind Compound to match contour

of seal plane. Grind smooth to touch (125 microinches or less) fill small voids with BMS 5-142.

Do the Air Leak and Seal Contact Surface Inspection to verify the seal contact on the seal ramp.

Refer to 747-100/200/300 AMM 52-09-02 or 747-

400 AMM 52-09-02 and SOPM 20-50-19 as an

accepted procedure.

5 Fairing Compound - -

Fill Fastener Holes with Fairing Compound. For

fastener holes that are not under the seal ramp,

grind flush with the Revel.

6 Fairing Compound - -

Apply fay surface seal between Plate and Corner

Reveal. Refer to 747-100/200/300 AMM 51-31-01

or 747-400 AMM 51-31-01 as an accepted procedure.

7 Fay Surface Seal BMS 5-95 -

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener.

If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65B88700 are used to

determine the part numbers used as substitutes.

FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 6 OF 8)

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BOEING SERVICE BULLETIN 747-53-2460
CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NN3K9 0.190 - 0.194

0.1890 -

0.1905

B Bolt BACB30VF3K3

Washer NAS1149D0363J

Nut BACN10YR3CD

C Rivet NAS1399D4A4 0.129 - 0.132

0.2021 -

0.2036

D Bolt (a) BACB30NY6K16X

0.2021 -

0.2036

Bolt (a) BACB30NY6K17X

Nut BACN10JC3CD

0.2177 -

0.2192

Bolt (a) BACB30NY6K16Y

0.2177 -

0.2192

Bolt (a) BACB30NY6K17Y

0.2646 -

0.2661

E Bolt (b) BACB30NY8K16X

0.2802-

0.2817

Bolt (b) BACB30NY8K16Y

Nut BACN10YT4CD

F Bolt ((c) BACB30NX6K3Y 0.216 - 0.219

Collar (c) BACC30R6

Bolt (c) BACB30NX8K3 0.247 - 0.250

Collar (c) BACC30BH8

G Bolt (d) BACB30NY6K3Y 0.216 - 0.219

Collar (d) BACC30AC6

Bolt (d) BACB30NW8K3 0.247 - 0.250

Collar (d) BACC30BL8

H Bolt BACB30NX8K3 0.247 - 0.250

Collar BACC30BH8

I Bolt BACB30NX8K4X 0.263 - 0.266

Collar BACC30BH8

J Nutplate BACN10JN3

K Nutplate BACN10JR3

FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 7 OF 8)

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BOEING SERVICE BULLETIN 747-53-2460
CODE NAME PART NUMBER HOLE DIA NOTES

L Rivet BACR15GF3D4 0.098 - 0.103

(a) Bolts of 2 diameters and 2 grip lengths are included in the kit. Use the smallest hole diameter that

will produce a clean hole. Use the appropriate grip length bolt. Refer to 747-100/200/300 SRM 51-

30-02 or 747-400 SRM 51-40-02.

(b) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean

hole. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

(c) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean

hole. Use the BACC30R6 Collar with the BACB30NX6K3Y Bolt. Use the BACC30BH8 Collar with

the BACB30NX8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

(d) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce a clean

hole. Use the BACC30AC6 Collar with the BACB30NY6K3Y Bolt. Use the BACC30BL8 Collar with

the BACB30NW8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

FIGURE 7: DOOR CORNER REVEAL - REMOVAL AND INSTALLATION FOR WELD REPAIR

(SHEET 8 OF 8)

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BOEING SERVICE BULLETIN 747-53-2460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one Corner Reveal.

STEP TASK NAME PART NUMBER QTY NOTES

Remove all the finish from

the Corner Reveal.

1 Remove Finish - 1

Refer to 747-100/200/300

AMM 51-21-01 or 747-

400 AMM 51-21-01 as an

accepted procedure.

Fusion weld repair as

given in BAC 5975, Class

B, using filler material ER

4043 per AWS A5.10 or

AMS 4190

2 Weld Crack - 1

Machine welded area to

original contour. Machine

to 125 microinch finish or

better.

3 Machine Weld Area - 1

Heat to 300 to 320 degrees Fahrenheit for 1 to

6 hours.

65B11751-601 or 1

65B11751-602

4 Heat Treat Corner Reveal

FIGURE 8: DOOR CORNER REVEAL - WELD REPAIR

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

Inspect for cracks. Do a

10 power visual and a

Dye Penetrant inspection.

Refer to SOPM 20-20-02

as an accepted procedure.

65B11751-601 or 1

65B11751-602

5 Inspect Corner Reveal

Restore finish to the Corner Reveal. Alodine and

apply 1 coat of BMS 10-

11 Type 1 Primer. Refer

to 747-100/200/300 SRM

51-10-02 or 747-400

SRM 51-20-01 and

SOPM 20-41-02 as an

accepted procedure.

6 Apply Finish - 1

FIGURE 8: DOOR CORNER REVEAL - WELD REPAIR

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
FIGURE 9: DOOR CORNER REVEAL REMOVAL

(SHEET 1 OF 3)

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BOEING SERVICE BULLETIN 747-53-2460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each side of the airplane.

FIGURE 9: DOOR CORNER REVEAL REMOVAL

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

1 Remove / Discard Fasteners - 2 -

Remove / Keep Girt Bar Fitting - 1 -

Remove / Keep Plate - 1 -

2 Remove / Discard Fasteners - 2 -

3 Remove / Discard Fasteners - 18 -

Remove / Discard Corner Reveal - 1 See Flagnote 1

Shim - 1 if installed.

4 Remove / Discard Nutplates - 2 -

From the structure. Refer

to 747-100/200/300 AMM

20-30-08 and 747-400

AMM 20-30-08 as an accepted procedure.

5 Clean Sealant - -

The flag note numbers shown below agree with the numbers shown in the flag symbol in the figure.

FLAG NAME PART NUMBER QTY NOTES

NOTE

Some airplanes may have the nutplates attached

with rivets that go through the Corner Reveal and

the bracket below. For this configuration the nutplate attach rivets must be removed before the

Corner Reveal can be removed.

1 Fasteners - 4

FIGURE 9: DOOR CORNER REVEAL REMOVAL

(SHEET 3 OF 3)

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BOEING SERVICE BULLETIN 747-53-2460
FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 1 OF 9)

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FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 2 OF 9)

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FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 3 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each side of the airplane.

FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 4 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

65B11751-1 (Option- 1 Left side

al: 65B11751-7)

Upper Portion of

Corner Reveal

1 Position

65B11751-2 (Option- Right side

al: 65B11751-8)

Shim BACS40R011C044F 1 If required. See Flagnote 2

65B11751-3 (Option- 1 Left side

al: 65B11751-9)

Lower Portion of

Corner Reveal

2 Position

65B11751-4 (Option- Right side

al: 65B11751-10)

3 Back Drill Holes - 22 -

Temporary Fasten- - 4 -

ers

4 Install

5 Position Kept Threshold - 1 -

6 Back Drill Holes 0.190 - 0.199 3 -

Doorway Scuff - 1 -

Plate

7 Position Kept

8 Back Drill Holes 0.190 - 0.199 1 at nutplate location.

9 Position Kept Forward - 1

Corner Scuff Plate

10 Back Drill Holes 0.190 - 0.199 3 at nutplate locations.

11 Remove / Keep Corner Scuff Plate - 1 -

Doorway Scuff - 1 -

Plate

12 Remove / Keep

13 Remove / Keep Threshold - 1 -

Temporary Fasten- - 4 -

ers

14 Remove / Discard

Upper Corner Re- - 1

veal

Remove / Keep

Shim - 1

Lower Corner Re- - 1

veal

Remove / Keep

15 Position Nutplates - 7 -

16 Back Drill Holes - 14 -

17 Clean / Debur Holes - - All drilled holes.

FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 5 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME PART NUMBER QTY NOTES

Install rivets wet with BMS

5-95 Sealant.

18 Install Nut Plates BACN10JZ3B2 2

19 Install Nut Plates - 7 -

Install with Fay Surface

Sealant. See Flagnote 3.

Upper Corner Re- - 1

veal

20 Install / Kept

Shim - 1 If required. See Flagnote 2

Install with Fay Surface

Sealant. See Flagnote 3.

Lower Corner Re- - 1

veal

Install / Kept

Install wet with BMS 5-95

Sealant. See Flagnote 4.

Install Fasteners - 20

Fill the gap between the upper and lower corner reveals with sealant. Make the

sealant flush with both parts

of the reveal.

21 Apply Sealant BMS 5-95 -

22 Apply Fairing Compound EC-3587-B/A - See Flagnote 5 and 6.

Apply over Fairing Compound. Refer to SOPM 20-

41-02 or Operators equivalent procedure.

23 Apply Primer BMS 10-11 Type 1 -

Boeing Color 702 White

Refer to 747-100/200/300

AMM 51-21-02 or 747-400

AMM 51-21-02 as an accepted procedure.

24 Apply Enamel BMS 10-60 Type 1 -

Install wet with BMS 5-95

Sealant.

25 Install Fasteners - 2

Install with Fay Surface

Sealant. See Flagnote 7.

26 Install / Kept Plate - 1

Girt Bar Fitting - 1 -

Install with MIL-C-11796,

Class 3 corrosion preventive

compound to all areas of the

hole and on the fasteners.

Install Fasteners BACB30NN3K9 2

The flag note numbers shown below agree with the numbers shown in the flag symbols in the figure.

FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 6 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
FLAG NAME PART NUMBER QTY NOTES

NOTE

Some airplanes may have the nutplates attach

with rivets that go through the Corner Reveal and

the bracket below. For this configuration the nutplate attach rivets must be removed before the

Corner Reveal can be removed.

1 Fasteners - 4

Install Shim as required to maintain a maximum

gap of 0.010 gap. Finish with BMS 10-11 Type 1

Primer after delaminations are removed. Shim can

be installed with the primer wet or dry. Refer to

SOPM 20-41-02 as an accepted procedure.

2 Shim - 1

Apply fay surface seal between Outboard side of

Corner Reveal and Skin strap. Refer to 747-

100/200/300 AMM 51-31-01 or 747-400 AMM 51-

31-01 as an accepted procedure.

3 Fay Surface Seal BMS 5-95 -

Grinding off the end of Bolt is allowed. Grind so

that end of bolt is even with the surface of the

Corner Reveal. Do not grind the nut.

4 Grind Bolt -

Make a seal ramp between the Corner Reveal and

Door Frame. Grind Compound to match contour

of seal plane. Grind smooth to touch (125 microinches or less) fill small voids with BMS 5-142.

Do the Air Leak and Seal Contact Surface Inspection to verify the seal contact on the seal ramp.

Refer to SOPM 20-50-19 and 747-100/200/300

AMM 52-09-02 or 747-400 AMM 52-09-02 as an

accepted procedure.

5 Fairing Compound - -

Fill Fastener Holes with Fairing Compound. For

fastener holes that are not under the seal ramp,

grind flush with the Revel.

6 Fairing Compound - -

Apply fay surface seal between Plate and Corner

Reveal. Refer to 747-100/200/300 AMM 51-31-01

or 747-400 AMM 51-31-01 as an accepted procedure.

7 Fay Surface Seal BMS 5-95 -

The codes shown below agree with the letter shown in the upper left corner of the fastener symbols in the figure.

A number in the lower right corner gives the grip length of the fastener.

FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 7 OF 9)

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BOEING SERVICE BULLETIN 747-53-2460
If the grip length shown is not available at Boeing, fasteners supplied in kits may be one grip length longer than

indicated. Also, if any of the fastener part numbers are not available or have been superseded, substitute

fasteners may be supplied in Boeing kits, Boeing Document D-590 and Boeing drawing 65B88700 are used to

determine the part numbers used as substitutes.

CODE NAME PART NUMBER HOLE DIA NOTES

A Bolt BACB30NN3K9 0.190 - 0.194 -

B Bolt BACB30VF3K3 0.1890 - 0.1905 -

Washer NAS1149D0363J -

Nut BACN10YR3CD

C Rivet NAS1399D4A4 0.129 - 0.132 -

D Bolt (a) BACB30NY6K16X 0.2021 - 0.2036 -

Bolt (a) BACB30NY6K17X 0.2021 - 0.2036

Nut BACN10JC3CD - BACN10YT3CD optional (e)

Bolt (a) BACB30NY6K16Y 0.2177 - 0.2192 -

Bolt (a) BACB30NY6K17Y 0.2177 - 0.2192

E Bolt (b) BACB30NY8K16X 0.2646 - 0.2661 -

Bolt (b) BACB30NY8K16Y 0.2802- 0.2817

Nut BACN10YT4CD -

F Bolt (c) BACB30NX6K3Y 0.216 - 0.219 -

Collar (c) BACC30R6 -

Bolt (c) BACB30NX8K3 0.247 - 0.250

Collar (c) BACC30BH8 -

FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 8 OF 9)

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CODE NAME PART NUMBER HOLE DIA NOTES

G Bolt (d) BACB30NY6K3Y 0.216 - 0.219 -

Collar (d) BACC30AC6 -

Bolt (d) BACB30NW8K3 0.247 - 0.250

Collar (d) BACC30BL8 -

H Bolt BACB30NX8K3 0.247 - 0.250 -

Collar BACC30BH8 -

I Bolt BACB30NX8K4X 0.263 - 0.266 -

Collar BACC30BH8 -

J Nutplate BACN10JN3 - -

K Nutplate BACN10JR3 - -

L Rivet BACR15GF3D4 0.098 - 0.103 -

(a) Bolts of 2 diameters and 2 grip lengths are included in the kit. Use the smallest hole diameter

that will produce a clean hole. Use the appropriate grip length bolt. Refer to 747-100/200/300

SRM 51-30-02 or 747-400 SRM 51-40-02.

(b) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce

a clean hole. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM 51-40-02.

(c) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce

a clean hole. Use the BACC30R6 Collar with the BACB30NX6K3Y Bolt. Use the BACC30BH8

Collar with the BACB30NX8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400 SRM

51-40-02.

(d) Bolts of 2 diameters are included in the kit. Use the smallest hole diameter that will produce

a clean hole. Use the BACC30AC6 Collar with the BACB30NY6K3Y Bolt. Use the BACC30BL8

Collar with the BACB30NW8K3 Bolt. Refer to 747-100/200/300 SRM 51-30-02 or 747-400

SRM 51-40-02.

(e) If the BACN10YT3CD nuts are ever removed, discard them. Do not reuse BACN10YT( ) nuts.

FIGURE 10: 2-PIECE DOOR CORNER REVEAL INSTALLATION

(SHEET 9 OF 9)

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FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL

(SHEET 1 OF 3)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for one side of the airplane.

FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL

(SHEET 2 OF 3)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME IDENTIFICATION QTY MORE DATA

1 Inspect Corner Reveal Assy - 1 Do a Detailed Inspection for cracks.

Do a Detailed Inspection for a sharp

edge.

2 Inspect Corner Reveal Assy - 1

FIGURE 11: INSPECTION OF MACHINED REVEALS FOR CRACKS AND A SHARP EDGE DETAIL

(SHEET 3 OF 3)

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The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each corner reveal.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

The sharp edge the minimum amount

necessary to get the dimension shown.

Corner Reveal - -

Assy

1 Cut

Radius both cut edges and blend to get a

63 microinch or smoother surface roughness. Refer to SOPM 20-10-03 as an accepted procedure.

Corner Reveal - -

Assy

2 Blend

FIGURE 12: REMOVAL OF THE SHARP EDGE DETAIL FROM THE DOOR CORNER REVEAL

(SHEET 1 OF 2)

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STEP TASK NAME IDENTIFICATION QTY MORE DATA

The cut edge and adjacent upper and

lower surfaces (intensity 0.004A - 0.007A,

coverage 2.0, shot size 230 - 550). Refer

to SOPM 20-10-03 as an accepted procedure.

Corner Reveal - -

Assy

3 Shot Peen

Chemical conversion coating to the reworked area of the reveal. Refer to SOPM

20-43-03 as an accepted procedure.

4 Apply Finish - -

One coat of BMS 10-11, Type I primer to

the reworked area of the reveal. Refer to

SOPM 20-41-02 as an accepted procedure.

Apply Finish - -

FIGURE 12: REMOVAL OF THE SHARP EDGE DETAIL FROM THE DOOR CORNER REVEAL

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
FIGURE 13: REWORK OF A 1-PIECE LEFT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR CORNER

REVEAL

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each affected left side corner reveal.

NOTE: These rework instructions are only allowed on 65B11751-601 corner reveals which have been confirmed

to be machined from 6061-T6 plate, not 356 aluminum castings. See Figure 4 to determine material.

All 65B11751-605 corner reveals are machined from 6061-T6 plate.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

From the corner reveal. Refer

to SOPM 20-30-02 as an accepted procedure. (a)

1 Remove Finish - -

65B11751-601 or 1 Into two parts

65B11751-605

2 Cut Corner Reveal

radius both cut edges and blend

to get a 125 microinch or

smoother surface roughness.

Refer to SOPM 20-10-03 as an

accepted procedure.

65B11751-601 or -

65B11751-605

3 Blend Corner Reveal

All over both halves of the reveal, Intensity 0.006A. Refer to

SOPM 20-10-03 as an accepted

procedure.

65B11751-601 or -

65B11751-605

4 Shot Peen Corner Reveal

Chemical conversion coating to

all surfaces of both halves of the

reveal. Refer to SOPM 20-43-

03 as an accepted procedure.

5 Apply Finish - -

One coat of BMS 10-11, Type I

primer to all surfaces of both

halves of the reveal. Refer to

SOPM 20-41-02 as an accepted

procedure.

Apply Finish - -

Part mark. Refer to SOPM 20-

50-10 as an accepted procedure.

Upper Portion of 65B11751-7 1

Corner Reveal

6 Identify

Part mark. Refer to SOPM 20-

50-10 as an accepted procedure.

Lower Portion of 65B11751-9 1

Corner Reveal

7 Identify

Mark each set of reveals with

the following: "65B11751-11:

Matched set, do not use separately"

8 Identify Corner Reveal Set 65B11751-7 1

65B11751-9 1

(a) If necessary, also make sure that the sharp edge detail has been removed as shown in Figure 12.

FIGURE 13: REWORK OF A 1-PIECE LEFT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR CORNER

REVEAL

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
FIGURE 14: REWORK OF A 1-PIECE RIGHT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR

CORNER REVEAL

(SHEET 1 OF 2)

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99 of 106

BOEING SERVICE BULLETIN 747-53-2460
The step numbers shown below agree with the numbers shown in the circle symbols in the figure. The QTY

numbers shown below are the number of parts necessary for each affected left side corner reveal.

NOTE: These rework instructions are only allowed on 65B11751-602 corner reveals which have been confirmed

to be machined from 6061-T6 plate, not 356 aluminum castings. See Figure 4 to determine material.

All 65B11751-606 corner reveals are machined from 6061-T6 plate.

STEP TASK NAME IDENTIFICATION QTY MORE DATA

From the corner reveal. Refer

to SOPM 20-30-02 as an accepted procedure. (a)

1 Remove Finish - -

65B11751-602 or 1 Into two parts

65B11751-606

2 Cut Corner Reveal

radius both cut edges and blend

to get a 125 microinch or

smoother surface roughness.

Refer to SOPM 20-10-03 as an

accepted procedure.

65B11751-602 or -

65B11751-606

3 Adjust Corner Reveal

All over both halves of the reveal, Intensity 0.006A. Refer to

SOPM 20-10-03 as an accepted

procedure.

65B11751-602 or -

65B11751-606

4 Shot Peen Corner Reveal

Chemical conversion coating to

all surfaces of both halves of the

reveal. Refer to SOPM 20-43-

03 as an accepted procedure.

5 Apply Finish - -

One coat of BMS 10-11, Type I

primer to all surfaces of both

halves of the reveal. Refer to

SOPM 20-41-02 as an accepted

procedure.

Apply Finish - -

Part mark. Refer to SOPM 20-

50-10 as an accepted procedure.

Upper Portion of 65B11751-8 1

Corner Reveal

6 Identify

Part mark. Refer to SOPM 20-

50-10 as an accepted procedure.

Lower Portion of 65B11751-10 1

Corner Reveal

7 Identify

Mark each set of reveals with

the following: "65B11751-12:

Matched set, do not use separately"

8 Identify Corner Reveal Set 65B11751-8 1

65B11751-10 1

(a) If necessary, also make sure that the sharp edge detail has been removed as shown in Figure 12.

FIGURE 14: REWORK OF A 1-PIECE RIGHT SIDE DOOR CORNER REVEAL INTO A 2-PIECE DOOR

CORNER REVEAL

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
FIGURE 15: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS FOR CRACKS AND A

SHARP EDGE DETAIL

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 747-53-2460
FIGURE 16: LOGIC DIAGRAM FOR THE INSPECTION OF MACHINED REVEALS WITH SHARP EDGE

DETAIL REMOVED FOR CRACKS

(SHEET 1 OF 1)

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BOEING SERVICE BULLETIN 747-53-2460
The step number shown below agrees with the numbers shown in the circle symbols in the figure. The QTY

number shown below are the number of parts necessary for each airplane.

FIGURE 17: INSPECTION FOR ONE OR TWO-PIECE CORNER REVEALS

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
STEP TASK NAME IDENTIFICATION QTY MORE DATA

to identify installed onepiece or two-piece corner

reveals. (a)

1 Inspect Corner Reveal - 2

(a) If the separation line exists, a two-piece corner reveal is installed. The separation line should be filled

with BMS 5-95 sealant.

FIGURE 17: INSPECTION FOR ONE OR TWO-PIECE CORNER REVEALS

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
1. Purpose

a. Use this procedure to determine if the Corner Reveal is made from a 356-T6 aluminum casting or 6061

aluminum plate with a heat treat of T6 or T651.

b. This procedure uses a chemical etch and a 25X minimum visual inspection.

2. Equipment

a. Tools

(1) Sanding disks or paper - 320, 600, and 1200-grit silicon carbide

(2) 25X minimum portable microscope

(3) Cotton swabs

b. Chemicals

WARNING: NITRIC ACID, HYDROCHLORIC ACID, AND HYDROFLUORIC ACID ARE DANGEROUS

LIQUIDS. DO NOT BREATHE THEIR VAPORS. DO NOT GET THESE MATERIALS IN EYES, ON

SKIN, OR ON CLOTHING

(1) Hydrochloric acid (HCl), concentrated

(2) Nitric acid (HNO3), concentrated

(3) Hydrofluoric acid (HF), 48% concentrated

c. Reference Standard

(1) A test sample can be made on a scrap piece of 6061-T6 or 6061-T651 material, using the steps

given in this procedure.

3. Preparation of Surface for Chemical Etch

a. Identify the inspection area on each Corner Reveal.

b. Use the 320-grit sandpaper or grinding wheel to remove any visible roughness. Use water as a lubricant

and change directions by 90 degrees frequently in a circular motion

c. Use the 600-grit sandpaper or grinding wheel to make the surface smooth. Use water as a lubricant

and change directions by 90 degrees frequently in a circular motion

d. Finish with a 1200-grit sandpaper or grinding wheel repeating the same circular motion.

e. Rinse the surface with clean and fresh water.

4. Chemical Etch Preparation

Appendix A: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION PROCEDURE

(SHEET 1 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460
WARNING: NITRIC ACID, HYDROCHLORIC ACID, AND HYDROFLUORIC ACID ARE DANGEROUS

LIQUIDS. DO NOT MIX THESE MATERIALS ON THE AIRPLANES. DO NOT BREATHE THEIR VAPORS,

AND DO NOT GET THESE MATERIALS IN EYES, ON SKIN, OR ON CLOTHING.

a. Mix the following chemicals to make the Poulton's reagent:

(1) 12 parts HCl, concentrated

(2) 6 parts HNO3, concentrated

(3) 1 part HF, 48% concentrated

(4) 1 part water

5. Etch the Surface to Inspected.

a. Apply the Poulton's reagent with a cotton swab for 3-6 seconds or until the microstructure has an

adequate contrast

b. Rinse the surface with clean water to stop the reagent's action

c. Wipe the surface dry with a clean dry cloth

6. Inspect the Etched Surface

a. Use the 25X portable microscope, to inspect the etched surface. Inspect for the typical appearance of

dendrites in cast and solidified materials. Refer to the Boeing Photo Number 02d00901 for the difference

between a cast microstructure and a plate microstructure.

NOTE: If the microstructure is not clear, it may be necessary to use a polarizing filter or higher magnification

Appendix A: DOOR CORNER REVEAL - MATERIAL TYPE INSPECTION PROCEDURE

(SHEET 2 OF 2)

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BOEING SERVICE BULLETIN 747-53-2460